Beruflich Dokumente
Kultur Dokumente
Supplement
Crane Warm-up Procedures
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© 2017 Manitowoc
Published 3-30-2017, Control # 516-04
SECTION CONTENTS
Crane Warm-up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Swing Drive and Turntable Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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This Supplement provides information regarding the proper Transmission
warm-up procedures for operating the crane in colder
temperatures. The information provided here supplements Operating the transmission with a sump temperature below
the Operator and Service Manuals and must be used in normal operating temperature is limited to:
conjunction with these manuals. • operating in the neutral gear or
COLD CLIMATE ENGINE OPERATION • driving with an unloaded crane while not exceeding
1500 engine RPM and not exceeding half throttle.
Engine specific cold climate operation information is
Warm-up Procedures for Rough Terrain (RT) and
available through your Cummins dealer/service center under
Industrial Cranes:
Service Bulletin 3379009.
1. Engage the parking brake and apply the service brake.
CRANE WARM-UP PROCEDURES
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2. Shift the transmission into the highest gear and increase
The following procedures detail the actions that must be the engine RPM to 1500 for 15 seconds, then allow the
taken to properly warm the different crane components engine RPM to return to idle.
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before operating the crane. 3. Repeat Step 2 until the temperature of the transmission
NOTE: For temperatures below -9°C (15°F) refer to arctic sump reaches normal operating temperature.
lubricants and conditions in the Operator and Alternate Warm-up Procedures for Rough Terrain (RT)
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Service Manuals. and Industrial Cranes:
Before starting the crane, ensure the appropriate lubricants 1. Setup the crane on outriggers.
are used in order to provide lubrication for the prevailing
ambient temperatures in which the crane will operate in (a 2. Engage the transmission with 4-wheel drive selected (if
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list of lubricants and their temperature ranges can be found equipped) and allow crane to run at idle until the
in the Lubrication section of your crane’s Operator Manual, temperature of the transmission sump reaches normal
by contacting your local Manitowoc distributor, or by operating temperature.
contacting Manitowoc Crane Care directly). NOTE: Warm-up operation of 4-wheel drive transmission
engaged in 2-wheel drive only could cause
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transmission damage.
CAUTION
Alternate Warm-up Procedures for Truck Mount (TM/
Crane Damage Hazard!
TMS) Cranes:
Operating the crane with the incorrect lubricants and
fluids for the prevailing ambient temperature and/or failing 1. Setup the crane on outriggers.
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to adequately warm the crane prior to cold weather 2. Engage the transmission and allow crane to run at idle
operation can lead to a failure of a crane component or until the temperature of the transmission sump reaches
system. normal operating temperature.
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Warm-up Procedures for All Temperature Ranges: 1. Without operating the hoist function, warm the hydraulic
oil (see Hydraulic Oil System, page 2-2).
1. Upon startup, allow the engine to idle for 3 to 5 minutes
before operating with a load. 2. Once the hydraulic system is warm, operate the
unloaded hoist, in both directions, at low speeds several
2. Cold Engine Startup: After allowing the engine to warm times to prime all hydraulic lines with warm hydraulic oil
by idling it for 3 to 5 minutes, slowly increase the engine and to circulate gear lubricant through the planetary
speed to provide adequate lubrication to the bearings gear sets.
and to allow the oil pressure to stabilize.
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medium function speed (joystick position) until the fluid
Warm-up Procedures for Temperatures Below -7°C reaches at least 10°C (50°F). It is then recommended
(20°F): that all crane functions be cycled to remove cold fluid
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1. Ensure the boom is fully retracted and near maximum lift from all components and cylinders of the hydraulic
angle with no load applied. system. If there is any unusual sound coming from the
crane’s hydraulic pumps or motors, stop the operation
2. Rotate the superstructure at a speed of less than one- and engine immediately and contact a Manitowoc
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half RPM for at least two complete revolutions in one distributor.
direction, then rotate the superstructure at a speed of
less than one-half RPM for at least two complete • From 10°C to 4°C (50°F to 40°F): Crane operation with
revolutions in the opposite direction. a load is allowed with medium engine RPM and medium
function speed (joystick position) until the fluid reaches
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Axles at least 10°C (50°F).
Warm-up Procedures for Temperatures Below -35°C • From 95°C to 10°C (200°F to 50°F): Crane operation
(-30°F): with a load is allowed with no restrictions.
• Above 95°C (200°F): No crane operation is allowed. Let
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OPERATOR MANUAL 1
This manual has been prepared for and is considered part of -
RT770E
Crane Model Number
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This Manual is divided into the following sections:
SECTION 1 INTRODUCTION
SECTION 2 SAFETY
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SECTION 3 OPERATING CONTROLS AND PROCEDURES
SECTION 4 SET-UP AND INSTALLATION
SECTION 5 LUBRICATION
SECTION 6 MAINTENANCE CHECKLIST
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NOTICE
The crane serial number is the only method your distributor or the factory
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The crane serial number is identified on the builder’s decal attached to the
operator cab. Always furnish crane serial number when ordering parts
or communicating service problems with your distributor or the factory.
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PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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CALIFORNIA
PROPOSITION 65 WARNING
Battery posts, terminals, and related accessories contain
chemical lead and lead compounds, chemicals known to
the State of California to cause cancer, birth defects or
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TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Noise/vibration test results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Noise Level Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Vibration Level Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 T
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General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 C
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
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Synthetic Hoist Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
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Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Transporting the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Travel Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
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Work Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Personal Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
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Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Parking and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
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Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Boom Lights Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 O
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Crane Function Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Hoist Rotation Indicator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Exhaust System Cleaning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
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Boom Section 1/Section 2 Selector Switch and Indicator . . . . . . . . . . . . . . . . . . . . . 3-7
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Boom Manual/Automatic Mode Selector Switch and Indicator . . . . . . . . . . . . . . . . . 3-8
Boom A/B Mode Selector Switch and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Boom Recovery Mode Switch and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Steering Column Indicator and Gauge Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Swing Brake Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
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Parking Brake Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Light Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hydraulic Oil High Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Transmission Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
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Seat Back Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
A/C Heater, Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
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Seat Slide Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Seat Frame Slide Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Armrest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Hoist Rotation Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
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HRI Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Hydraulic Boost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Armrest Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Side Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
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Rated Capacity Limiter (RCL) and Work Area Definition System (WADS)
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Rated Capacity Limiter (RCL) Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Transmission Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
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General Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Stowing and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 O
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Unattended Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
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Accessing the Hoist Area (Fixed counterweight units only). . . . . . . . . . . . . . . . . . . . . . . 4-1
Travel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Working Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Installing Cable on the Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
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Boom Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Installing Wedge and Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Erecting and Stowing the Bi-fold Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Boom Extension Rigging Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Erecting the Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Stowing the Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Setting the Folding Swingaway Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Erecting and Stowing the Bi-fold Boom Extension with the 6.1 m (20 ft) Insert. . . . . . . 4-18
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Erecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Fixed Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Removable Counterweight (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
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SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lubricants and Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Standard Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Arctic Lubricants and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Steering and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Grove TOC-5
TABLE OF CONTENTS RT770E
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Weekly or 50 Hour Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
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TOC-6
RT770E OPERATOR MANUAL INTRODUCTION
SECTION 1
INTRODUCTION 1
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Noise/vibration test results . . . . . . . . . . . . . . . . . . 1-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Noise Level Test Results . . . . . . . . . . . . . . . . . . . 1-1 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Vibration Level Test Results . . . . . . . . . . . . . . . . . 1-2 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Serial Number Location . . . . . . . . . . . . . . . . . . . . . 1-2 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-5
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General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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Hoists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
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GENERAL Customer Support
NOTE: Throughout this manual, reference is made to left, Manitowoc and our distributor network want to ensure your
right, front, and rear when describing locations. satisfaction with our products and customer support. Your
These reference locations are to be considered as local distributor is the best equipped and most
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those viewed from the operator seat with the knowledgeable to assist you for parts, service and warranty
superstructure facing forward over the front of the issues. They have the facilities, parts, factory trained
carrier frame. personnel, and the information to assist you in a timely
manner. We request that you first contact them for
This Operator Manual provides important information for the
assistance. If you feel you need factory assistance, please
operator of the Model RT770E Grove Crane.
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The carrier frame incorporates an integral fifth wheel, to Includes/EN/changeofownership.cfm and complete the form.
which the rear axle is mounted, to provide axle oscillation.
Axle oscillation lockout is automatic when the superstructure NOISE/VIBRATION TEST RESULTS
rotates from the travel position.
The superstructure is capable of 360° rotation in either Noise Level Test Results
direction. All crane functions are controlled from the fully-
• When equipped with the CE certification package, the
enclosed cab mounted on the superstructure. The crane is
guaranteed sound power level is L wa 105 dB(A) as
equipped with a four-section, full power, sequenced and
synchronized boom. Additional reach is obtained by utilizing measured by Directive 2000/14/EC and 80 db(A) at the
an optional swingaway boom extension. Lifting is provided crane operator position as measured by Annex G.1 of
by a main hoist and an optional auxiliary hoist. EN 13000:2010+A1:2014.
Vibration Level Test Results Hand Transmitted Vibrations, and ISO/DIS 8041 -
Human Response Vibration Measuring Instrumentation.
• At the operator station with closed cab operation,
vibration levels are less than 0.5 m/s/s for Whole Body
SERIAL NUMBER LOCATION
Vibration exposure and are less than 2.5 m/s/s for Hand
Arm Vibration exposure when measured according to Refer to Figure 1-1.
89/392/EEC Community Legislation on Machinery per
Whenever contacting your local Grove distributor or
standard ISO 2631/1 - Evaluation of Human Exposure to
Manitowoc Crane Care have the serial number of the crane
Work Body Vibration, ISO 5349 - Guidelines for the
available.
Measurement and Assessment of Human Exposure to
Manual Cover
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Inside Cab
Frame
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7813-1
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1
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1 7
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3 4 5 6
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14 13
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12 12
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FIGURE 1-2
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16 18
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26
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7671-2
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24 23
25
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15 Crane Steps
27 DEF Tank
16 Boom Pivot Pin
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17 Hydraulic Valves and Swing Motor Cover
18 Swingaway Extension
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Wheelbase . . . . . . . . . . . . . . . . . . . 4.06 m (160 in) Brakes
Overall Crane Length . . . . . . . . . . . 13.6 m (44.6 ft)
Overall Crane Width . . . . . . . . . . . . .3.33 m (11.0 ft) Type . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Disc
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Overall Crane Height . . . . . . . . . . . 3.60 m (10.9 ft) Size . . . . . . . . . . . . . . 470 x 16 mm (18.5 x 0.63 in)
Outside Turning Radius
2 Wheel Steer . . . . . . . 11.342 m (37 ft 2.55 in) Wheels and Tires
4 Wheel Steer . . . . . . .6.744 mm (22 ft 1.5 in)
Outside Curb Clearance Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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2 Wheel Steer . . . . . . . . . 11.7 m (38 ft 5.88 in) Torque . . . . . . . . . 461 to 488 Nm (340 to 360 lb-ft)
4 Wheel Steer . . . . . . . . . . 7.1 m (23 ft 3.5 in) Tire Size
Outrigger Spread Standard . . . . . . . . . . . .29.5 x 25, 28 ply rating
Retracted. . . . . . . . . . . . . . . .3.18 m (10 ft 5 in) Optional . . . . . . . . . . . . 29.5R25, 34 ply rating
Mid Extend . . . . . . . . . . . . . .5.28 m (17 ft 4 in) NOTE: For roading and lifting pressures, refer to the Load
Fully Extended . . . . . . . . . . .7.11 m (23 ft 4 in)
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Chart Book in the cab.
Capacities Swing Gearbox
Fuel Tank . . . . . . . . . . . . . . . . . . . . . 280 L (74 gal)
Coolant System . . . . . . . . . . . . . . . . . . See Engine Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . 36:1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications Output Torque . . . . . . . . . . . . . . . . . . . 45,000 in-lb
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 L (40 qt)
DEF Tank . . . . . . . . . . . . . . . . . . . . . . . 19 L (5 gal) Electrical . . . . . . . . . . . . . . . . . . . . . . 20 Slip Rings
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ports
Torque Converter Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ports
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Pump #3 Cable
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Diameter . . . . . . . . . . . . . . . . . 19 mm (0.75 in)
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Length-Main. . . . . . . . . . . . . . . . 198 m (650 ft)
Output - @ loaded engine speed Length-Aux. . . . . . . . . . . . . . . . . 199 m (653 ft)
Section 1 . . . . . . . . . . . . 120 L/min (31.7 gpm) Max. Permissible Line Pull (6x36)
. . . . . . . . . . . . . . . . . . . . . . . . . 74.7 kN (16,800 lb)
Hoists Max. Single Line Speed . . . . . 153 m/min (500 fpm)
Drum Dimensions
Diameter . . . . . . . . . . . . . . . . . 381 mm (15 in)
Length (Standard) . . . . . . . .467 mm (18.38 in)
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SECTION 2
SAFETY INFORMATION
SECTION CONTENTS
Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . 2-27
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . 2-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Hoist Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
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Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Accidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Synthetic Hoist Rope . . . . . . . . . . . . . . . . . . . . . . 2-30
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Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Operator Information . . . . . . . . . . . . . . . . . . . . . . . 2-3
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Operator Qualifications . . . . . . . . . . . . . . . . . . . . . 2-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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Transporting the Crane. . . . . . . . . . . . . . . . . . . . . 2-31
Rated Capacity Limiter (RCL) Systems
(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Anti-Two-Blocking Device . . . . . . . . . . . . . . . . . . . 2-5 Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Working Area Limiter (If Equipped). . . . . . . . . . . . 2-5 Personal Considerations . . . . . . . . . . . . . . . . . . . 2-32
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Crane Stability/Structural Strength. . . . . . . . . . . . 2-6 Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Load Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
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The importance of safe operation and maintenance cannot To alert personnel to hazardous operating practices and
be overemphasized. Carelessness or neglect on the part of maintenance procedures, safety messages are used
throughout the manual. Each safety message contains a It is not meant to cover every conceivable circumstance
safety alert symbol and a signal word to identify the hazard’s which could arise. It is intended to present basic safety
degree of seriousness. precautions that should be followed in daily operation.
Safety Alert Symbol Because you are the only part of the crane that can think and
reason, your responsibility is not lessened by the addition of
operational aids or warning devices. Indeed, you must guard
against acquiring a false sense of security when using them.
They are there to assist, not direct the operation. Operational
This safety alert symbol means ATTENTION! aids or warning devices can be mechanical, electrical,
Become alert - your safety is involved! Obey all safety electronic, or a combination thereof. They are subject to
messages that follow this symbol to avoid possible death failure or misuse and should not be relied upon in place of
or injury. good operating practices.
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You are the only one who can be relied upon to assure the
Signal Words safety of yourself and those around you. Be a professional
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and follow the rules of safety.
Remember, failure to follow just one safety precaution could
DANGER cause an accident that results in death or serious injury to
personnel or damage to equipment. You are responsible for
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Identifies hazards that will result in death or serious injury
the safety of yourself and those around you.
if the message is ignored.
Warning Signs
Refer to the Parts Manual for a drawing indicating the
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WARNING location of warning signs on the crane.
Identifies hazards that may result in death or serious
injury if the message is ignored. ACCIDENTS
Following any accident or damage to equipment, the
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injury if the message is ignored. to service until it is thoroughly inspected for any evidence of
damage. All damaged parts must be repaired or replaced as
authorized by your Manitowoc distributor and/or Manitowoc
Crane Care.
CAUTION
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OPERATOR INFORMATION with crane operations and the hazards involved. Such a
person shall meet the operator qualifications specified in
You must read and understand this Operator Manual and Occupational Safety and Health Administration (OSHA)
the Load Chart before operating your new crane. You must Regulations (United States Federal Law), in ASME B30.5
also view and understand the supplied safety video. This American National Standard, or in any other applicable
manual and Load Chart must be readily available to the federal, state or local laws.
operator at all times and must remain in the cab (if equipped)
or operator’s station while the crane is in use. Ensure that all personnel working around the crane are
thoroughly familiar with safe operating practices. You must
The Operator Manual supplied with and considered part of be thoroughly familiar with the location and content of all
your crane must be read and completely understood by each placards and decals on the crane. Decals provide important
person responsible for assembly, disassembly, operation instructions and warnings and must be read prior to any
and maintenance of the crane. operational or maintenance function.
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No personnel shall be allowed to climb onto the crane or Refer to the Parts Manual for this crane for the locations of all
enter the crane cab or operator’s station unless performance safety decals.
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of their duties require them to do so, and then only with
knowledge of the operator or other qualified person. You must be familiar with the regulations and standards
governing cranes and their operation. Work practice
Allow No One other than the operator to be on the crane requirements may vary slightly between government
while the crane is operating or moving, unless they are regulations, industry standards, and employer policies so a
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seated in a two-man cab. thorough knowledge of all such relevant work rules is
necessary.
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it is important that you have specific training on the particular weight of the load does not exceed the crane ratings at
crane you will be operating. the radius where the load is to be handled.
Training is ESSENTIAL for proper crane operation. Never • When a Boom Angle or Radius Indicator is inoperative
jeopardize your own well-being or that of others by or malfunctioning, the radius or boom angle shall be
attempting to operate a crane on which you have not been determined by measurement.
trained.
• When an Anti-Two-Blocking Device, Two-Blocking
You must be mentally and physically fit to operate a crane. Damage Prevention Device or Two-Block Warning
Never attempt to operate a crane while under the influence Device is inoperative or malfunctioning, the designated
of medication, narcotics, or alcohol. Any type of drug could person responsible for supervising the lifting operations
i m pa i r p h y s i c a l , v i s u a l a n d m e n ta l r e a c t i o n s , a n d shall establish procedures, such as assigning an
capabilities. additional signal person to furnish equivalent protection.
This does not apply when lifting personnel in load-line
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As operator of this crane, you are granted the authority to
supported personnel platforms. Personnel shall not be
stop and refuse to lift loads until safety is assured.
lifted when anti-two-block devices are not functioning
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properly.
OPERATIONAL AIDS
• When a Boom Length Indicator is inoperative or
Operational aids are accessories that provide information to malfunctioning, the designated person responsible for
facilitate operation of a crane or that take control of particular supervising the lifting operations shall establish the
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functions without action of the operator when a limiting boom lengths at which the lift will be made by actual
condition is sensed, as stated in the latest revision of the measurements or marking on the boom.
ASME B30.5, and ASME B30.8 standards. Examples of
such devices include, but are not limited to, the following: • When a Level Indicator is inoperative or malfunctioning,
other means shall be used to level the crane.
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anti-two-block device, rated capacity indicator, rated capacity
limiter, boom angle or radius indicator, boom length indicator,
crane level indicator, hoist drum rotation indicator, load Rated Capacity Limiter (RCL) Systems (If
indicator, and wind speed indicator. Equipped)
Manitowoc remains committed to providing reliable products Your crane may be equipped with an RCL system which is
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that enable users and operators to safely lift and position intended to aid the operator. An RCL is a device that
loads. Manitowoc has been an industry leader in the automatically monitors radius, load weight, and load rating
incorporation of operational aids into the design of its cranes. and prevents movements of the crane, which would result in
Federal law requires that cranes be properly maintained and an overload condition.
kept in good working condition. The manuals that Manitowoc
Test daily for proper operation. Never interfere with the
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is accomplished as soon as is reasonably possible. If upon these electronic aids in place of good operating
immediate repair or recalibration of an operational aid is not practices can cause an accident.
possible and there are exceptional circumstances which
Know the weight of all loads and always check the capacity
justify continued short-term use of the crane when
of the crane as shown on the Load Chart before making any
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Anti-Two-Blocking Device the boom is lowered. Keep load handling devices a minimum
of 107 cm (42 in) below the boom nose at all times.
This crane should have a functional Anti-Two-Block and
Control Lock-Out System. Test daily for proper operation. Two-blocking can be prevented. Operator awareness of the
hazards of two-blocking is the most important factor in
Two-blocking occurs when the load block (hook block, preventing this condition. An Anti-Two-Block System is
headache ball, rigging, etc.) comes into physical contact with intended to assist the operator in preventing dangerous two-
the boom (boom nose, sheaves, jib, etc.). Two-blocking can block conditions. It is not a replacement for operator
cause hoist rope (wire rope or synthetic rope), rigging, awareness and competence.
reeving, and other components to become highly stressed
and overloaded in which case the hoist rope may fail Never interfere with the proper functioning of operational
allowing the load, block, etc. to free fall. aids or warning devices.
Two-blocking is more likely to occur when both the main and Working Area Limiter (If Equipped)
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auxiliary hoist lines are reeved over the main boom nose and
jib nose respectively. An operator, concentrating on the This crane may be equipped with a working area limiter as
part of the RCL system, designated as either Work Area
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specific line being used, may telescope or lower the boom
allowing the other hoist line attachment to contact the boom Definition System (WADS) or Working Range Limiter (WRL).
or jib nose, thus causing damage to the sheaves, or causing You must read and understand the operator manual before
the hoist rope to fail, dropping the lifting device to the ground operating the working area limiter system. Become familiar
with all proper operating procedures and with the
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and possibly injuring personnel working below.
identification of symbol usage.
Caution must be used when lowering the boom, extending
the boom or hoisting up. Let out load line(s) simultaneously The working area limiter is intended to be used as an aid to
to prevent two-blocking the boom tip(s) and the hook block, the operator. It is not a substitute for safe crane operating
practices, experience and good operator judgements.
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etc. The closer the load is carried to the boom nose the more
important it becomes to simultaneously let out hoist rope as
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CRANE STABILITY/STRUCTURAL slightly off the ground and recheck the stability before
STRENGTH proceeding with the lift. Determine the weight of the load
before you attempt the lift.
To avoid death or serious injury, ensure that the crane is on a
Unless lifting within On Rubber capacities, outrigger beams
firm surface with load and crane’s configuration within
and jack cylinders (plus center front stabilizer, if equipped)
capacity as shown on the crane’s Load Chart and notes.
must be properly extended and set to provide precise
Ensure all pins and floats are properly installed and outrigger leveling of the crane. Tires must be clear of the ground
beams are properly extended before lifting on outriggers. On before lifting on outriggers.
models equipped with outriggers that can be pinned at the
mid-extend position (vertical stripe, if applicable), the
outriggers must also be pinned when operating from the mid-
extend position.
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Use adequate cribbing under outrigger floats to distribute
weight over a greater area. Check frequently for settling.
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Read and follow the following safety decal for cranes with
center front stabilizers.
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Load Charts
Load Charts represent the absolute maximum allowable
Carefully follow the procedures in this Operator Manual loads, which are based on either tipping or structural
limitations of the crane under specific conditions. Knowing
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position selected.
Load Chart capacities are based on freely suspended loads.
Before swinging the superstructure over the side when the
outriggers are retracted, check the Load Chart for backwards You must use the appropriate Load Chart when determining
stability. the capability of the crane in the configuration required to
perform the lift.
Long cantilever booms can create a tipping condition when
in an extended and lowered position. Retract the boom Maximum lifting capacity is available at the shortest radius,
proportionally with reference to the capacity of the applicable minimum boom length, and highest boom angle.
Load Chart. Do not remove the Load Charts from the crane.
Check crane stability before lifting loads. Ensure the
outriggers (or tires if lifting on rubber) are firmly positioned on Work Site
solid surfaces. Ensure the crane is level, brakes are set, and Prior to any operation, you must inspect the entire work site,
the load is properly rigged and attached to the hook. Check including ground conditions, where the crane will travel and
the Load Chart against the weight of the load. Lift the load
operate. Be sure that the surfaces will support a load greater Wind can have a significant effect on loads that may be lifted
than the crane’s weight and maximum capacity. by a crane. Wind forces act differently on a crane depending
upon the direction from which the wind is blowing (e.g., wind
Be aware of all conditions that could adversely effect the
on the rear of the boom can result in decreased forward
stability of the crane.
stability, wind on the underside of the boom can result in
Be aware of the danger for people entering the working area. decreased backward stability, wind on the side of the boom
Do not allow unnecessary personnel in the vicinity of the can result in structural damages, etc.)
crane while operating.
Wind forces can exert extreme dynamic loads. Manitowoc
recommends that a lift not be made if the wind can cause a
WIND FORCES loss of control in handling the load.
There are basic principles that must be followed while Wind forces can be determined by typical visible effects on
operating in windy conditions. This information has been the landscape.To assist you in determining prevailing wind
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provided to assist in determining safe operation in windy conditions, refer to Table 2-1.
conditions.
NOTE: The wind speed corresponding to the Beaufort
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Always use extreme caution when windy conditions exist. scale in the table is mean wind speed at 10 m
NEVER exceed the rated capacity shown on the Load Chart. (33 ft) elevation over a period of 10 minutes.
Always check the Load Chart to ensure the load to be
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lifted is within the rated capacity of the crane.
Breeze extended.
Moderate
4 7.9 28.4 17.7 Dust and loose paper raised. Small branches begin to move.
Breeze
Fresh Branches of a moderate size move. Small trees in leaf begin to
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7 High Wind 17.1 61.6 38.3 Whole trees in motion. Effort needed to walk against the wind.
Some twigs broken from trees. Cars veer on road. Progress on
8 Gale 20.7 74.5 46.3
foot is seriously impeded.
Some branches break off trees, and some small trees blow
9 Strong Gale 24.4 87.8 54.6
over. Construction/temporary signs and barricades blow over.
10 Storm 28.4 102.2 63.5 Trees are broken off or uprooted, structural damage likely.
Wind Speeds
The maximum permissible wind speed referred to in the load
charts is the 3-second wind gust speed measured at the
boom tip height and is designated as V(z). This value is
either recorded at boom tip or calculated based on mean
wind speed recorded at crane operation site. For lift planning
purposes only, the 3-second wind gust speed, V(z), may be
calculated based on mean wind speed reported at http://
www.windfinder.com “Super Forecast”.
This 3-second wind gust is assumed to act on the entire
crane and the load. The wind effect on the load can be
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conservatively estimated as:
a) If V(z) is ≤ 13.4 m/s (30 mph), then the allowable
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load is the published rated capacity from the Load Chart.
b) If V(z) is > 13.4 m/s (30 mph) and is ≤ 20.1 m/s
(45 mph), the allowable load is the published rated
capacity multiplied by the Capacity Reduction Factor
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from Table 2-4 (metric) or Table 2-6 (non-metric).
NOTE: This condition is limited to operation with the main
boom on fully extended outriggers only.
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c) If V(z) is > 20.1 m/s (45 mph), then lifting is NOT
permitted. Cease lifting operations and lower and retract
the boom.
In both cases a) and b) above, the lift may also be limited by
the projected wind area of the load Ap and by the wind drag
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13.4 m/s < V(z) < 20.1 m/s V(z) > 20.1 m/s (45 mph)
V(z) < 13.4 m/s (30 mph) (30 mph < V(z) < 45 mph)
Main Boom Use Main Boom on
Fully Extended Outriggers ONLY
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Lifting is not permitted.
Cease Lifting Operations
Allowable load =
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Calculate Allowable Load
Published Rated Capacity
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Ap = maximum height X maximum length
Determine Ap See Figure 2-2
Calculate
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Determine Cd of Load Awr (load) = Ap X Cd
NO
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Ap / Allowable Load < 0.5 m /t ?
(Ap / Allowable Load < 0.0025 ft2/lb)
YES
Awr (Allow) = 1.2 m2/t
(Awr (Allow) = 0.0059 ft2/lb)
YES
Awr (Allow) >Awr (load) ?
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NO
Calculate Ratio:
Awr (load) / Awr (Allow)
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YES
Maximum Permissible
Wind Speed > V(z)?
NO
V(z) = 3 second gust wind speed at boom tip, m/s (mph) Awr (load) = Actual Wind Resistance Area for the Load, m2(ft)
Ap = Projected Wind Area of Load, m2 (ft2) Awr (Allow) = Allowable Wind Resistance Area of the Load, m2 (ft2
Cd = air drag coefficient of load
FIGURE 2-1
Determination of 3-second wind gust speed at boom Size and Shape of the load:
tip height:
These rated capacities are also based on the assumption
The following example illustrates how to calculate 3-second that the Wind Resistance Area of load, Awr(load) is not more
wind gust speed at boom tip height based on mean wind than 0.0012 square meters per kilogram (0.0059 sq.ft per
speed recorded by the device located at the crane operation pound of load. (See below Formulas 2.4 and 2.5.)
site:
The load capacities shall be reduced to account for the larger
V(z) is the 3-second wind gust speed at boom tip wind resistance area of load and 3-second wind gust speed
height Z then: at boom tip height. Use tag lines when the wind gust speed is
Metric, with Z [m] and V [m/s] above 13.4 m/s (30 mph) to help control the movement of the
load. Manitowoc recommends that a lift not be made if
V(z) = [(Z/10)0.14 + 0.4] x V (2.1) the wind can cause a loss of control in handling the
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Non-metric, with Z [ft] and V [mph] load.
V(z) = [(Z/33)0.14 + 0.4] x V (2.2) The lift may also be limited by the projected wind area of the
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where: load Ap and by the wind drag coefficient Cd. This limit can be
determined by comparing the actual wind resistance area of
V [m/s] [mph] - Mean wind speed at 10 m (22 ft) the load with the allowable wind resistance area.
elevation (upper limit of Beaufort scale) Awr(load) = Ap x Cd (2.3)
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Example: Suppose you want to lift the load with the where:
maximum boom tip height of 30 m (100 ft) and the recorded
mean wind speed by the device located at the crane Awr(load) [m2] [ft2] . - Wind resistant area of the load
operation site is 5.5 m/s (13 mph). This mean wind speed of
Ap [m2] [ft2] - projected wind area,
5.5 m/s (13 mph) corresponds to Beaufort number 4 (see
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Table 2-1). The maximum wind velocity according to the Cd - wind drag coefficient.
Beaufort scale of 4 is 7.9 m/s (17.7 mph).
Ap is determined by using the calculation of maxi-
The mean wind speed (upper limit of Beaufort number) at mum height x maximum length (see Figure 2-3).
10 m (33 ft) height, to be used for calculation is:
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V = 7.9 m/s (17.7 mph) For Cd, refer to Table 2-2. If the Cd cannot be cal-
Boom tip height for this lift is Z = 30 m (100 ft) culated or estimated, use a value of 2.4.
8m
8m
Wind Wind
1m 3m
Ap = 8 m2 Ap = 24 m2
3m 1m
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25 ft
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25 ft
Wind
Wind
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3 ft 10 ft
FIGURE 2-2
(Table 2-2).
If the wind drag coefficient of the load cannot be estimated or
determined, it shall be assumed that (Cd) = 2.4.
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Shape Cd
If the wind resistant area of the load Awr(load) is greater than
the allowable wind resistant area Awr(allow), the ratio can be
used to determine a permissible wind speed V(z) for the load
1.1 to 2.0
using Table 2-3.
0.3 to 0.4
0.6 to 1.0
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0.8 to 1.2
0.2 to 0.3
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0.05 to 0.1
Turbine Blade or
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Complete Rotor
Approximately 1.6
8384-2
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Table 2-3 Awr Ratio and Permissible Wind Speed V(z) - Non - metric
Note: Permissible and rated wind speeds in this table are the 3-second gust wind speeds at boom tip height.
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8383-1
FIGURE 2-3
Table 2-4 Example-Capacity Reduction Factors for Wind Speed V(z) Greater than 13.4 m/s - Metric
(Only for lifting with main boom on fully extended outriggers, with or without stowed extension)
For wind speed V(z) (3-second gust speed at boom tip height) V(z) > 13.4 m/s ≤ 20.1 m/s, the Reduced Capacity
shall be calculated by multiplying the Published Rated Capacity by the following factors:
Main Boom Length in Meters
Wind Speed
V(z) > 13.4 m/s 10.9 12.2 15.2 18.4 21.3 24.4 27.4 30.5 33.5
< 20.1 m/s
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Factor 0.9 0.9 0.8 0.8 0.8 0.8 0.8 0.7 0.6
Wind resistance area of load, Awr(load) shall not exceed maximum allowable wind resistance area Awr(allow).
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Maximum allowable wind resistance area, [m2] Awr(allow) = 0.0012 x calculated reduced capacity in kg.
Wind resistance area of load, Awr(load) = projected wind area Ap x wind drag coefficient Cd for the load.
For wind resistance Area of load, Awr (load) > maximum allowable wind resistance area, Awr(allow) refer to crane
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Operator Manual.
Table 2-5 Awr Ratio and Permissible Wind Speed V(z) - Metric
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Note: Permissible and rated wind speeds in this table are the 3-second gust wind speeds at boom tip height.
1.2 1.4 1.6 1.8 2
Ratio:
Maximum Permissible Wind Speed (m/s)
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For Rated Capacity at 13.4 m/s 12.2 11.4 10.6 10.0 9.5
For Allowable Capacity at 20.1 m/s 18.3 17.0 15.9 15.0 14.2
Example 1: Crane Configuration: reduce the allowable load. Per Table 2-4, the Factor for main
boom length of 27.4 m is 0.8, the allowable load is:
• boom length = 27.4 m,
m(allow) = 0.8 x 15,050 = 12,040 kg
• load radius = 9 m,
• wind speed is measured at V(z) ≤ 20.1 m/s. This reduced capacity load has an allowable wind resistance
area of:
From the Rated Load Chart Example - Metric
(Figure 2-3), at maximum permissible wind speed, V(z) = Awr(allow) = 0.0012 x 12,040 = 14.45 m2
13.4 m/s, the rated lifting c apacity m ( a l l o w ) for th is
configuration is 15,050 kg. Lifting Limits at wind speed V(z) > 13.4 m/s and
≤ 20.1 m/s, at this configuration:
The maximum allowable wind resistance area of load is
• Maximum load 12,040 kg
At wind speeds greater than 13.4 m/s, it is not permissible to Load example 1.3a:
lift a load greater than 12,040 kg, even if the wind resistance
With large wind resistance area of the load Awr(load),
area of the load is less than 14.45 m2.
• Load to be lifted of 14,000 kg,
Refer to the information from the above crane configuration,
examine several load conditions. • Projected Wind Area Ap = 21.85 m2,
Load example 1.1: • Wind Drag Coefficient Cd = 1.2
With known Wind Drag Coefficient of the load Cd, and the wind resistance area of load can be estimated as:
• load to be lifted of 11,200 kg, Awr(load) = Ap X Cd = 21.85 x 1.2 = 26.22 m2
• Projected Wind Area Ap = 9.20 m2, Refer to the above Lifting Limits at wind
speed V(z) > 13.4 m/s and ≤ 20.1 m/s. Comparing the load
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• Wind Drag Coefficient Cd = 1.5 to the allowable:
wind resistance area of load can be estimated as • Is the load to be lifted less than allowable load?
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Awr(load) = Ap x Cd = 9.2 x 1.5 = 13.8 m2 14,000 kg ≤ 12,040 kg NO
Conclusion: This load is NOT permissible to lift in wind
Refer to the above Lifting Limits at wind speed V(z) speed up to 20.1 m/s.
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> 13.4 m/s and ≤ to 20.1 m/s. Comparing the load and wind
Refer to the above Lifting Limits at wind
resistant area to the allowable:
speed V(z) < 3.4 m/s. Comparing the load to the allowable:
• Is the load to be lifted less than allowable load?
• Is the load to be lifted less than allowable load?
11,200 kg ≤ 12,040 kg YES
14,000 kg ≤ 15,050 kg YES
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• Is Awr(load) less than Awr(allow) ?
The maximum permissible wind speed for this load is
13.8 m2 ≤ 14.45 m2 YES 13.4 m/s, depending on the wind resistance area of the load.
Conclusion: This load is permissible to lift in wind speed up • Is Awr(load) less than Awr(allow)?
to 20.1 m/s.
26.22 m2 ≤ 18.06 m2 NO
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10.6 m/s.
NOTE: If exact Wind Drag Coefficient is not known, it shall
be assumed as 2.4. Conclusion: This load is permissible to lift in wind speed up
to 10.6 m/s only.
• the wind resistance area of load can be estimated as
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Refer to the above Lifting Limits at V(z) > 13.4 m/s With large wind resistance area of the load Awr(load) ,
and ≤ 20.1 m/s. Comparing the load and wind resistant area • Load to be lifted of 8,000 kg,
to the allowable:
• Projected Wind Area Ap = 15.25 m2,
• Is the load to be lifted less than allowable load?
10,000 kg ≤ 12,040 kg YES • Wind Drag Coefficient Cd = 1.3
• Is Awr(load) less than Awr(allow) ? the wind resistance area of load can be estimated as
2 m2
13.08 m ≤ 14.45 YES Awr(load) = Ap x Cd = 15.25 x 1.3 = 19.83 m2
Conclusion: This load is permissible to lift in wind speed up Refer to the above Lifting Limits at wind speed V(z)
to 20.1 m/s. > 13.4 m/s and ≤ 20.1 m/s. Comparing the load and wind
resistant area to the allowable:
Ratio = 1.37
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ratio of 1.37 (rounded to next higher table value of 1.4) is
17.0 m/s.
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Conclusion: This load is permissible to lift in wind speed up
to 17.0 m/s only.
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8382-1
FIGURE 2-4
Table 2-6 Example-Capacity Reduction Factors for Wind Speed V(z) Greater than 30 mph - Non-metric
(Only for lifting with main boom on fully extended outriggers, with or without stowed extension)
For wind speed Vz (3-second gust speed at boom tip height) is greater > 30> mph ≤ 45 mph, the Reduced Capacity
shall be calculated by multiplying the Published Rated Capacity by the following factors:
Main Boom Length in Feet
Wind Speed
Vz< 30 mph 36 40 50 60 70 80 90 100 110
< 45 mph
Factor 0.9 0.9 0.8 0.8 0.8 0.8 0.8 0.7 0.5
Wind resistance area of load, Awr(load), shall not exceed maximum allowable wind resistance area Awr(allow).
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Maximum allowable wind resistance area in [ft2],Awr (allow) = 0.0059 x calculated reduced capacity in lb.
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Wind resistance area of load, Awr(load) = projected wind area Ap x wind drag coefficient Cd for the load.
For wind resistance area of load, Awr (load) > maximum allowable wind resistance, Awr (allow), refer to crane Operator
Manual.
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Table 2-7 Awr Ratio and Permissible Wind Speed V(z) - Non-Metric
Note: Permissible and rated wind speeds in this table are the 3-second gust wind speeds at boom tip height.
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1.2 1.4 1.6 1.8 2
Ratio:
Maximum Permissible Wind Speed (mph)
For Rated Capacity@ 30 mph 27.4 mph 25.4 mph 23.7 mph 22.4 mph 21.2 mph
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For Allowable Capacity@ 45 mph 41.1 mph 38.0 mph 35.6 mph 33.5 mph 31.8 mph
speed) above 13.4 m/s (30 mph) and maximum permissible Lifting Limits at wind speed V(z) < 30 mph at this
wind speeds with various combinations of lifted load and configuration:
wind resistance area. • Maximum load 25,200 lb
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The maximum allowable wind resistance area of load is: • Maximum load 20,160 lb
Example, wind speeds greater than 13.4 m/s is NOT • Projected Wind Area Ap = 180 ft2,
permissible to lift a load greater than 20,160 lb, even if the
• Wind Drag Coefficient Cd = 1.2
wind resistance area of the load is less than 119 ft2.
the wind resistance area of load can be estimated as:
Refer to the above crane configuration for the following load
conditions: Awr(load) = Ap x Cd = 180 x 1.2 = 216 ft2
Load example 2.1: Refer to the above Lifting Limits at wind speed V(z) >
30 mph and ≤ 45 mph. Comparing the load to the allowable:
With known Wind Drag Coefficient of the load Cd,
• Is the load to be lifted less than allowable load?
• load to be lifted of 19,500 lb, 22,000 lb ≤ 20,160 lb NO
• Projected Wind Area Ap = 70 ft2, Conclusion: This load is NOT permissible to lift in wind
speed up to 45 mph.
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• Wind Drag Coefficient Cd = 1.5
Refer to the above Lifting Limits at wind speed V(z) up to
then the wind resistance area of load can be estimated as 30 mph. Comparing the load to the allowable:
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Awr(load) = Ap x Cd = 70 x 1.5 = 105 ft2 Is the load to be lifted less than allowable load?
22,000 lb ≤ 25,200 lb . . . . . . . . . . . . . . . . . . . . YES
Refer to the above Lifting Limits at wind speed V(z) > 30
mph and ≤ 45 mph. Comparing the load and wind resistant The permissible wind speed for this load is 30 mph,
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area to the allowable: depending on the wind resistance area of the load.
• Is the load to be lifted less than allowable load? • Is Awr(load) less than Awr(allow),?
19,500 lb ≤ 20,160 lb YES 216 ft2 ≤ 149 ft2 . . . . . . . . . . . . . . . . . . . . . . . . . NO
• Is Awr(load) less than Awr(allow)? Conclusion: This load is NOT permissible to lift in wind
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105 ft2 ≤ 119 ft2 YES speed at 30 mph, but permitted to lift at a reduced wind
speed calculated as follows:
Conclusion: This load is permissible to lift in wind speed up
to 45 mph.
Ratio = 1.45
Load example 2.2:
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With unknown Wind Drag Coefficient of the load Cd, From Table 2-7, the maximum permissible wind speed at
• Load to be lifted of 18,000 lb, ratio of 1.45 (rounded to next higher table value of 1.6) is
23.7 mph.
• Projected Wind Area Ap = 45 ft2,
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> 30 mph and ≤ 45 mph. Comparing the load and wind • Wind Drag Coefficient Cd = 1.3
resistant area to the allowable:
the wind resistance area of load can be estimated as:
• Is the load to be lifted less than allowable load?
18,000 lb ≤ 20,160 lb YES Awr(load) = Ap x Cd = 125 x 1.3 = 162 ft2
• Is Awr(load) less than Awr(allow)? Refer to the above Lifting Limits at wind speed V(z)
2 > 30 mph and ≤ 45 mph. Comparing the load and wind
108 ft ≤ 119 ft2 YES resistant area to the allowable:
Conclusion: This load is permissible to lift in wind speed up
• Is the load to be lifted less than allowable load?
to 45 mph.
12,000 lb ≤ 20,160 lb YES
Load example 2.3a: • Is Awr(load) less than Awr(allow),?
With large wind resistance area of the load Awr(load), 162 ft2 ≤ 119 ft2 NO
• Load to be lifted of 22,000 lb,
Conclusion: This load is NOT permissible to lift in wind • Outriggers are not properly extended and set. On
speed up to 45 mph, but permitted to lift at a reduced wind models equipped with outriggers that can be pinned at
speed calculated as follows: the mid-extend position, the outriggers must also be
pinned when operating from the mid-extend position.
Ratio = 1.37
• Cribbing under the outrigger pads is inadequate.
From Table Table 2-7, the maximum permissible wind speed • The crane is improperly operated.
at ratio of 1.37 (rounded to next higher table value of 1.4) is Do not rely on the crane’s tipping to determine your lifting
38.0 mph. capacity.
Conclusion: This load is permissible to lift in wind speed up Be sure the hoist line is vertical before lifting. Do not subject
to 38.0 mph only. the crane to side loading. A side load can tip the crane or
cause it to fail structurally.
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Lifting Operations
Load Chart capacities are based on freely suspended loads.
Before lifting, position the crane on a firm surface, properly Do not pull posts, pilings, or submerged articles. Be sure the
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extend and set the outriggers, and level the crane. load is not frozen or otherwise attached to the ground before
Depending on the nature of the supporting surface, lifting.
adequate cribbing may be required to obtain a larger bearing
surface. If you should encounter a tipping condition, immediately
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lower the load with the hoist line and retract or elevate the
The crane is equipped with a bubble level that should be boom to decrease the load radius. Never lower or extend the
used to determine whether the crane is level. The load line boom; this will aggravate the condition.
can also be used to estimate the levelness of the crane by
checking to be sure it is in-line with the center of the boom at Use tag lines whenever possible to help control the
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all points on the swing circle. movement of the load.
If the jib, or auxiliary boom nose is to be used, ensure the When lifting loads, the crane will lean toward the boom and
electrical cable and the weight for the Anti-Two-Block Switch the load will swing out, increasing the load radius. Ensure the
are properly installed and the Rated Capacity Limiter (RCL) crane’s capacity is not exceeded when this occurs.
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is programmed for the crane configuration. Refer to the RCL Do not strike any obstruction with the boom. If the boom
operator manual supplied with the crane. should accidentally contact an object, stop immediately.
Verify the crane’s capacity by checking the Load Chart Inspect the boom. Remove the crane from service if the
against the weight of the load. Then, lift the load slightly at boom is damaged.
first to ensure stability before proceeding with the lift. Never push or pull with the crane boom.
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Be sure the load is properly rigged and attached. Always Avoid sudden starts and stops when moving the load. The
determine the weight of the load before you attempt to lift it inertia and an increased load radius could tip the crane over
and remember that all rigging (slings, etc.) and lifting devices or cause it to fail structurally.
(hook block, jib, etc.) must be considered part of the load.
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• The load and crane’s configuration is not within the Do not add material to the counterweight to increase
capacity as shown on the applicable Load Chart and capacity. United States Federal law prohibits modification or
notes. additions which affect the capacity or safe operation of the
equipment without the manufacturer’s written approval.
• The ground is soft and/or the surface conditions are [29CFR 1926.1434]
poor.
Outrigger Lift Off • Ensure the load lines are directly over the attach points
to avoid side loading and transfer of loading from one
Regarding “lifting” of an outrigger pad during craning crane to the other.
activities, be advised that the rated loads for these cranes,
as indicated on the crane’s Load Chart, do not exceed 85% • Do not travel. Lift only from a stationary position.
of the tipping load on outriggers as determined by SAE J765
OCT90 “Cranes Stability Test Code.” An outrigger pad may Tilt-Up Panel Lifting
lift off the ground during operation of the crane within the Requirements and recommendations regarding operation
capacity limits of the Load Chart, yet the crane will not have and use of Grove Cranes are stated on decals and in the
reached instability. The “balance point” for stability testing Operator and Safety Handbook and other manuals provided
according to SAE and Manitowoc criteria is a condition of with each specific model machine. Using the subject crane to
loading wherein the load moment acting to overturn the perform tilt-up panel lifting with two hoist lines poses new and
crane is equal to the maximum moment of the crane different hazards than does normal lifting use.
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available to resist overturning. This balance point or point of
instability for a crane does not depend on “lifting” of an Therefore, the following additional precautions must be
taken if it is necessary for the crane to be used to perform tilt-
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outrigger but rather on comparison of the “opposing” load
moments. up panel lifting using a crane equipped with two hoists:
The occurrence of an outrigger lifting from the ground is often • The crane must be set up and operated in accordance
attributed to the natural flex in the crane’s frame. This may with Grove’s instructions in the Operator and Safety
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happen when lifting a load in certain configurations within the Handbook, Load Capacity Chart, and decals affixed to
capacity limits of the Load Chart and is not necessarily an the crane.
indication of an unstable condition. • The wire rope from the main hoist shall be reeved over
Provided the crane is properly set up, the crane is in good the main boom nose reeved for two parts of line.
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working condition, that all operator’s aids are properly • The wire rope from the auxiliary hoist shall be reeved
programmed, that the qualified crane operator adheres to over the auxiliary boom nose reeved for one part of line.
the instructions found in the applicable Load Chart, Operator
Manual and decals on the crane, the crane should not be • The load shall be connected with the main hoist line
unstable. connected to the end closest to crane and the auxiliary
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planned and coordinated by a designated person. If it is • The RCL hoist selection shall be set to main hoist and
necessary to perform a multi-crane lift, the operator shall be two parts offline.
responsible for assuring that the following minimum safety • The wire rope and sheaves shall be inspected prior to
precautions are taken: and following the lifting operations for chaffing or
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• Use outriggers on cranes so equipped. • The load shall be controlled to prevent rotation of the
load and to ensure the load stays in line with the boom.
• Calculate the amount of weight to be lifted by each crane
and attach slings at the correct points for proper weight • The load must be balanced with the auxiliary: load line
distribution. not taking more than half the load at any time during the
lift. The RCL will not be providing coverage for the line
pull of the auxiliary hoist line.
• The effect of wind loads on the crane and panel shall be • Pile extraction using only the crane’s hoist line is unsafe
taken into consideration. Operations shall be halted if and not pe rmitt ed s inc e load values ca nnot be
the wind can cause a loss of control in handling the load. accurately determined. Only pile extraction devices that
do not transmit vibration or shock loading into the crane
• The main hoist line shall be used to raise the panel into
are permitted. All possible precautionary measures shall
the vertical position.
be taken to prevent shock loads or vibration from being
Ensure that all personnel working on and around the crane imposed on crane components, either directly through
are properly trained and thoroughly familiar with operational the hoist cable or indirectly from ground borne vibration.
functions of the crane and safe operating and work practices. • The load lines shall be kept vertical at all times during
Personnel should be thoroughly familiar with regulations and pile driving and pile extraction operations.
standards governing cranes and their operation. Work
practices may vary slightly between government regulations, • The operator and other personnel associated with the
industry standards, local and job-site rules and employer pile driving and pile extraction operation shall have read
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policies so a thorough knowledge of and compliance with all and understood all safety standards applicable to crane
relevant work rules is necessary. operations as well as being thoroughly trained in the
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safe operation of pile driving and extracting equipment.
PILE DRIVING AND EXTRACTING Crane Equipment
Pile driving and extracting are applications approved by • Hoists shall be equipped with a cable follower to aid in
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Manitowoc, provided all equipment is operated within factory proper spooling of cable.
guidelines. The following operating requirements must be
used during pile driving and extracting with a Manitowoc • All cable retainer pins and cable guides/retainers shall
mobile hydraulic crane: be in place.
Pile driving and pile extraction using a mobile crane • All jibs must be removed from the machine before pile
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introduces many variable and unknown factors that must be driving or extraction begins.
considered when using a crane for this application. Because
• All hoist hooks shall be equipped with a positive locking
of these factors, discretion must be exercised when pile
latch.
driving or pile extraction is being considered.
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of the ground. pads remain in place. Cranes which utilize pinned boom
• The combined weight of the driver or extractor, piling, sections shall be inspected daily to ensure the pinning
leads, attachments, etc., shall not exceed 80% of the mechanism operates properly and to check for undue
published load chart values for on-outriggers operation. wear at the pins and pinning plates. The hoist cable shall
be inspected daily to ensure no chafing or wear is
• The pile driver or pile extractor and attachments shall be
occurring.
kept clear of the boom nose at all times.
• The pile driver and piling shall be suspended from a
hoist cable with sufficient line speed to meet or exceed
the rate of descent of the driver and piling to preclude
impact loading or vibration from being induced into the
boom and crane structure.
• Pile driving or extracting shall be restricted to over the
main boom only and shall not be permitted over a jib.
ELECTROCUTION HAZARD
Thoroughly read, understand, and abide by all applicable
federal, state, and local regulations regarding operation of
DANGER
cranes near electric power lines or equipment.
Electrocution Hazard!
United States federal law prohibits the use of
cranes closer than 6 m (20 ft) to power sources Manitowoc cranes are not equipped with all features
up to 350 kV and greater distances for higher required to operate within OSHA 29CFR1926.1408,
voltages unless the line’s voltage is known Power Line Safety, Table A clearances when the power
[29CFR1910.180 and 29CFR1926, subpart CC].
lines are energized.
To avoid death or serious injury, Manitowoc rec-
ommends that all parts of crane, boom, and If operation within 3 m (10 ft) of any power lines cannot be
load be kept at least 6 m (20 ft) away from all avoided, the power utility must be notified and the power
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electrical power lines and equipment less than l i n e s m us t b e d e - e n e r g i z e d a n d g r o u n d e d b ef o re
350 kV.
performing any work.
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If contact is ever accidentally made with a power line and any
part of this crane, its rigging or load, never touch the crane or
even approach or come near the crane.
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Electrocution can occur even without direct contact with the
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Crane operation is dangerous when close to an energized operator, are responsible for alerting all personnel of
electrical power source. Exercise extreme caution and dangers associated with electrical power lines and
prudent judgement. Operate slowly and cautiously when in equipment. Do not allow unnecessary personnel in the
the vicinity of power lines. vicinity of the crane while operating. Permit no one to lean
against or touch the crane. Permit no one, including riggers
Before operating this crane in the vicinity of electrical power
and load handlers, to hold the load, load lines, tag lines, or
lines or equipment, notify the power utility company. Obtain
rigging gear.
positive and absolute assurance that the power has been
turned off. If the load, hoist rope, boom, or any portion of the crane
contacts or comes too close to an electrical power source,
This crane is not insulated. Always consider all parts of the
everyone in, on, and around the crane can be seriously
load and the crane, including the hoist rope, wire rope,
injured or killed.
pendant cables, and tag lines, as conductors. You, the
Most overhead power lines are not insulated. Treat all Appoint a reliable and qualified signal person, equipped with
overhead power lines as being energized unless you have a loud signal whistle or horn and voice communication
reliable information to the contrary from the utility company equipment, to warn the operator when any part of the crane
or owner. or load moves near a power source. This person should
have no other duties while the crane is working.
The rules in this Operator Manual must be followed at all
times, even if the electrical power lines or equipment have Tag lines should always be made of non-conductive
been de-energized. materials. Any tag line that is wet or dirty can conduct
electricity.
The safest way to avoid electrocution is to stay away from
electrical power lines and electrical power sources. Do not store materials under power lines or close to
electrical power sources.
It is not always necessary to contact a power line or power
source to become electrocuted. Electricity, depending on Electrocution Hazard Devices
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magnitude, can arc or jump to any part of the load, load line,
or crane boom if it comes too close to an electrical power The use of insulated links, insulated boom cages/guards,
source. Low voltages can also be dangerous. proximity warning devices, or mechanical limit stops does
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not assure that electrical contact will not occur. Even if codes
Set-Up and Operation or regulations require the use of such devices, failure to
follow the rules listed here may result in serious injury or
During crane use, assume that every line is energized (“hot”
death. You should be aware that such devices have
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or “live”) and take the necessary precautions.
limitations and you should follow the rules and precautions
Set up the crane in a position such that the load, boom, or outlined in this manual at all times even if the crane is
any part of the crane and its attachments cannot be moved to equipped with these devices.
within 6 m (20 ft) of electrical power lines or equipment. This
Insulating links installed into the load line afford limited
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includes the crane boom (fully extended to maximum height,
protection from electrocution hazards. Links are limited in
radius, and length) and all attachments (jibs, rigging, loads,
their lifting abilities, insulating properties, and other
etc.). Overhead lines tend to blow in the wind so allow for
properties that affect their performance. Moisture, dust, dirt,
lines’ movement when determining safe operating distance.
oils, and other contaminants can cause a link to conduct
A suitable barricade should be erected to physically restrain electricity. Due to their capacity ratings, some links are not
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the crane and all attachments (including the load) from effective for large cranes and/or high voltages/currents.
entering into an unsafe distance from electrical power lines
The only protection that may be afforded by an insulated link
or equipment.
is below the link (electrically downstream), provided the link
Plan ahead and always plan a safe route before traveling has been kept clean, free of contamination, has not been
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under power lines. Rider poles should be erected on each scratched or damaged, and is periodically tested (just before
side of a crossing to assure sufficient clearance is use) for its dielectric integrity.
maintained.
Boom cages and boom guards afford limited protection from
electrocution hazards. They are designed to cover only the
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• Proximity devices are advertised to detect the existence When operating near transmitter/communication towers
of electricity and not its quantity or magnitude. where an electrical charge can be induced into the crane or
load:
• Some proximity devices may detect only alternating
current (AC) and not direct current (DC). • The transmitter shall be deenergized OR,
• Some proximity devices detect radio frequency (RF) • Tests shall be made to determine if an electrical charge
energy and others do not. will be induced into the crane or load.
• Most proximity devices simply provide a signal (audible, • The crane must be provided an electrical ground.
visual, or both) for the operator; this signal must not be
• If taglines are used, they must be non-conductive.
ignored.
• Every precaution must be taken to dissipate induced
• Sometimes the sensing portion of the proximity devices
voltages. Consult a qualified RF (radio frequency)
becomes confused by complex or differing arrays of
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Consultant. Also refer to local, state, and federal codes
power lines and power sources.
and regulations.
Do not depend on grounding. Grounding of a crane affords
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When operating cranes equipped with electromagnets, you
little or no p rotec tion f rom elect ric al h aza rds. The
must take additional precautions. Permit no one to touch the
effectiveness of grounding is limited by the size of the
magnet or load. Alert personnel by sounding a warning
conductor (wire) used, the condition of the ground, the
signal when moving a load. Do not allow the cover of the
magnitude of the voltage and current present, and numerous
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electromagnet power supply to be open during operation or
other factors.
at any time the electrical system is activated. Shut down the
Electrical Contact crane completely and open the magnet controls switch prior
to connecting or disconnecting magnet leads. Use only a
If the crane should come in contact with an energized power non-conductive device when positioning a load. Lower the
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source, you must: magnet to the stowing area and shut off power before
leaving the operator’s cab (if equipped) or operator’s station.
1. Stay in the crane cab. Don’t panic.
2. Immediately warn personnel in the vicinity to stay away. PERSONNEL HANDLING
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3. Attempt to move the crane away from the contacted The American Society of Mechanical Engineers issued a
power source using the crane’s controls which may have new American National Standard entitled, Personnel Lifting
remained functional. Systems, ASME B30.23-2011:
4. Stay in the crane until the power company has been This Volume establishes the design criteria, equip-
contacted and the power source has been de-energized. ment characteristics, and operational procedures
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crane upon contacting a power source. If it is absolutely to meet the standards for personnel handling equip-
necessary to leave the operator’s station, jump completely ment, such as ANSI/SIA A92 (Aerial Platforms).
clear of the crane. Do not step off. Hop away with both feet The equipment and implementation requirements
together. Do not walk or run. listed in this Volume are not the same as that estab-
lished for using equipment specifically designed
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Following any contact with an energized electrical source, and manufactured for lifting personnel. Hoisting
equipment complying with the applicable Volumes
the Manitowoc distributor must be immediately advised of of the ASME B30 Standard shall not be used to lift
the incident and consulted on necessary inspections and or lower personnel unless there are no less hazard-
repairs. Thoroughly inspect the hoist rope and all points of ous alternatives to providing access to the, area
contact on the crane. Should the dealer not be immediately where work is to be performed. The lifting or lower-
available, contact Manitowoc Crane Care. The crane must ing of personnel using ASME B30-compliant hoist-
ing equipment is prohibited unless all applicable
not be returned to service until it is thoroughly inspected for requirements of this volume have been met.
any evidence of damage and all damaged parts are repaired
or replaced as authorized by your Manitowoc distributor or This new standard is consistent with the U.S. Department of
Manitowoc Crane Care. Labor, Occupational Safety and Health Administration
(O SHA) re gu lat io n s fo r Con st ru c tion th at stat e, in
Special Operating Conditions and 29CFR1926.1431:
Equipment General requirements. The use of a crane or der-
rick to hoist employees on a personnel platform is
Never operate the crane during an electrical thunderstorm. prohibited, except when the erection, use, and dis-
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• The requirements of the applicable national, state and
• NEVER get on or off a moving crane.
local regulations and safety codes are met.
• NEVER allow anyone other than the operator to be on
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• A determination has been made that use of a crane to
this crane while the machine is operating or traveling.
handle personnel is the least hazardous means to
perform the work. • NEVER allow anyone on the hoist access platform while
traveling.
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• The crane operator shall be qualified to operate the
specific type of hoisting equipment used in the The following standards and regulations regarding personnel
personnel lift. handling are available by mail at the following addresses:
• The crane operator must remain at the crane controls at • ASME (formerly ANSI) B30 Series American National
all times when personnel are off the ground. Safety Standards For Cableways, Cranes, Derricks,
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Hoists, Hooks, Jacks, and Slings; ASME B30.5, Mobile
• The crane operator and occupants have been instructed
And Locomotive Cranes, and ASME B30.23, Personnel
in the recognized hazards of personnel platform lifts.
Lifting Systems, are available by mail from the ASME, 22
• The crane is in proper working order. Law Drive, Fairfield, New Jersey, 0700-2900
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• The crane must be equipped with a boom angle • US DOL/OSHA Rules and Regulations are available by
indicator that is visible to the crane operator. mail from the Superintendent of Documents, PO Box
371954, Pittsburgh, PA, 15250-7954.
• The crane's Load Chart is affixed at the operator’s
station and readily accessible to the operator. The total
weight of the loaded personnel platform and related
ENVIRONMENTAL PROTECTION
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rigging shall not exceed 50 percent of the rated capacity Dispose of waste properly! Improperly disposing of waste
for the radius and configuration of the crane. can threaten the environment.
• The crane is level within one percent of level grade and Potentially harmful waste used in Manitowoc cranes includes
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located on a firm footing. Cranes with outriggers shall — but is not limited to — oil, fuel, grease, coolant, air
have them all deployed following manufacturer's conditioning refrigerant, filters, batteries, and cloths which
specifications. have come into contact with these environmentally harmful
• The crane's Operator Manual and other operating substances.
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manuals are at the operator ’s station and readily Handle and dispose of waste according to local, state, and
accessible to the operator. federal environmental regulations.
• The platform meets the requirements as prescribed by When filling and draining crane components, observe the
applicable standards and regulations. following:
• For hoist rope suspended platforms: • Do not pour waste fluids onto the ground, down any
- The crane is equipped with a hook that can be drain, or into any source of water.
closed and locked, eliminating the throat opening. • Always drain waste fluids into leak proof containers that
- The crane is equipped with a functional anti-two- are clearly marked with what they contain.
block device. • Always fill or add fluids with a funnel or a filling pump.
- The platform is properly attached and secured to the • Immediately clean up any spills.
load hook.
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operations.
• Do not use your hand or any part of your body to check
Shut down the crane while making repairs or adjustments. for hydraulic fluid leaks when the engine is running or
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Always perform a function check after repairs have been the hydraulic system is under pressure. Fluid in the
made to ensure proper operation. Load tests should be hydraulic system can be under enough pressure that it
performed when structural or lifting members are involved. will penetrate the skin, causing serious injury or death.
Use a piece of cardboard, or piece of paper, to search
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Follow all applicable safety precautions in this manual when for leaks. Wear gloves to protect your hands from
performing crane maintenance as well as crane operations. spraying fluid.
Keep the crane free of mud, dirt, and grease at all times. • If any hydraulic fluid is injected into the skin, obtain
Dirty equipment introduces hazards, wears-out faster, and medical attention immediately or gangrene may result.
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makes proper maintenance difficult. Cleaning solutions used
should be non-flammable, non-toxic and appropriate for the • Do not attempt to repair or tighten any hydraulic hose or
job. fitting while the engine is running, or when the hydraulic
system is under pressure.
Routine maintenance and inspection of this crane must be
performed by a qualified person(s) according to the • Never disconnect any hydraulic lines unless the boom is
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recommendations in the Manitowoc Crane Care fully lowered, the engine is shut off, and the hydraulic
Maintenance and Inspection Manual. Any questions pressure is relieved. To relieve hydraulic pressure, stop
regarding procedures and specifications should be directed the engine, turn the ignition switch to RUN and move the
to your Manitowoc distributor. hydraulic controls in both directions several times.
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m o t i o n b e t w e e n p i n c h p o i n ts w h e n p e r f o r m i n g Tires
maintenance and to avoid such areas when movement
is possible.
• Do not allow persons to stand near extending or
lowering outriggers. Foot crushing could occur WARNING
Before performing any maintenance, service or repairs on Possible equipment damage and/or
the crane: personal injury!
• The boom should be fully retracted and lowered and the Driving the crane with a tire and split-rim assembly under
load placed on the ground. inflated at 80% or less of its recommended pressure can
cause the wheel and/or tire to fail. Per OSHA Standard
• Do not get under a raised boom unless the boom is 1910.177(f)(2), when a tire has been driven under inflated
blocked up safely. Always block up the boom before at 80% or less of its recommended pressure, it must first
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doing any servicing that requires the boom to be raised. b e c o m pl e t e l y d e f l at e d , r e m o v e d f r o m th e a xl e ,
disassembled, and inspected before re-inflation.
• Stop the engine and disconnect the battery.
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• Controls should be properly tagged. Never operate the Inspect the tires for nicks, cuts, embedded material, and
crane if it is tagged-out nor attempt to do so until it is abnormal wear.
restored to proper operating condition and all tags have
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been removed by the person(s) who installed them. Ensure all lug nuts are properly torqued.
After maintenance or repairs: Ensure pneumatic tires are inflated to the proper pressure
(refer to the Load Chart). When inflating tires, use a tire
• Replace all guards and covers that have been removed. gauge, clip-on inflator, and extension hose which will permit
standing clear of the tire while inflating.
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• Remove all tags, connect the battery, and perform a
function check of all operating controls.
HOIST ROPE
• Consult with Manitowoc Crane Care to determine if load
Use only the hoist rope specified by Manitowoc as indicated
testing is required after a structural repair is performed.
on the crane’s Capacity Chart. Substitution of an alternate
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Lubrication hoist rope may require the use of a different permissible line
pull and, therefore, require different reeving.
The crane must be lubricated according to the
NOTE: Hoist rope may be purchased by contacting
manufacturer’s recommendations for lubrication points, time
Manitowoc Crane Care.
intervals, and types. Lubricate at more frequent intervals
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• Any kinking, bird caging, crushing, corrosion, or other ASME and similar organizations. See the Service
damage resulting in distortion of the rope structure. Manual for inspection procedures.
• Rope that has been in contact with a live power line or When inspecting ropes and attachments, keep all parts
has been used as a ground in an electric circuit (eg. of your body and clothing away from rotating hoist drums
welding) may have wires that are fused or annealed and and all rotating sheaves. Never handle the rope with
must be removed from service. bare hands.
• In standing ropes, more than three (3) breaks in one Some conditions that lead to problems in wire rope
rope lay in sections beyond the end connection or more systems include:
than two (2) broken wires at an end connection.
- Sheaves that are too small, worn or corrugated
• Core deterioration, usually observed as a rapid cause damage to a wire rope.
reduction in rope diameter, is cause for immediate
- Broken wires mean a loss in strength.
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removal of the rope.
- Kinks permanently damage a wire rope and must be
The following is a brief outline of the basic information
avoided.
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required to safely use wire rope.
- Wire ropes are damaged by knots. Wire rope with
• Wire ropes wear out. The strength of a wire rope begins
knots must never be used.
to decrease when the rope is put to use and continues to
decrease with each use. Wire rope will fail if worn-out,
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- Environmental factors such as corrosive conditions
overloaded, misused, damaged or improperly and heat can damage a wire rope.
maintained.
- Lack of lubrication can significantly shorten the
• The nominal strength, sometimes called catalog useful life of a wire rope.
strength, of a wire rope applies only to a new, unused
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- Contact with electrical wires and resulting arcing will
rope.
damage a wire rope.
• The nominal strength of a wire rope should be
• An inspection should include verification that none of the
considered the straight line pull which will actually break
specified removal criteria for this usage are met by
a new unused rope. The nominal strength of a wire rope
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• In the U.S.A., regular inspections of the wire rope and When installing a new rope:
keeping of permanent records signed by a qualified • Keep all parts of your body and clothing away from
person are required by OSHA for almost every wire rope rotating hoist drums and all rotating sheaves.
application. The purpose of the inspection is to
determine whether or not a wire rope may continue to be • Never handle the wire rope with bare hands.
safely used on the application. Inspection criteria, • Follow proper instructions for removing rope from a reel.
including number and location of broken wires, wear and
elongation, have been established by OSHA, ANSI, • Apply back tension to the storage/payoff reel of the new
rope to insure tight, even spooling onto the hoist drum.
• Operate the new rope - first through several cycles at Ensure sheaves carrying ropes that can be momentarily
light load and then through several cycles at unloaded are equipped with close fitting guards or other
intermediate load to allow the rope to adjust to operating devices to guide the rope back into the groove when the load
conditions. is reapplied. Ensure sheaves in the lower load block are
equipped with close fitting guards that will prevent the ropes
When using a wedge socket:
from becoming fouled when the block is lying on the ground
• Always inspect socket, wedge, and pin for correct size with loose ropes.
and condition.
To attain maximum hoist rope life and minimize hook block
• Do not use parts that are damaged, cracked, or rotation, it is recommended that even numbers of parts-of-
modified. line be used in multiple-part reeving whenever possible.
• Assemble the wedge socket with live end of rope aligned The use of nylon (polyamide) sheaves, as compared with
with the centerline of pin and assure proper length of tail metallic sheaves, may change the replacement criteria of
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(dead end) protrudes beyond the socket. rotation-resistant hoist rope.
NOTE: The use of cast nylon (polyamide) sheaves will
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Synthetic Hoist Rope
substantially increase the service life of rope.
For detailed information concerning synthetic hoist rope, However, conventional rope retirement criteria
refer to KZ100 Synthetic Crane Hoist Line Manual P/N based only upon visible wire breaks may prove
9828100734 available by contacting Manitowoc Crane Care. inadequate in predicting rope failure. The user of
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cast nylon sheaves is therefore cautioned that a
During installation and setup, care must be taken to avoid
retirement criteria should be established based
overlap and crossing of wire rope and synthetic hoist ropes.
upon the user’s experience and the demands of his
Always make daily inspections of the hoist rope, keeping in application.
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mind that all hoist rope will eventually deteriorate to a point
where it is no longer usable. Refuse to work with worn or Batteries
damaged hoist rope.
Battery electrolyte must not be allowed to contact the skin or
During regular inspections, operator shall ensure that crane eyes. If this occurs, flush the contacted area with water and
surfaces such as wear pads, sheaves, etc have not been consult a doctor immediately.
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addressed before the synthetic hoist rope is used • If equipped, disconnect battery with the battery
in that same position. disconnect switch before disconnecting the ground
battery cable. For cranes with a Cummins engine using
Sheaves an engine ECM:
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position.
c. Remove the ECM power fuse.
d. Remove negative battery cables.
• Do not break a live circuit at the battery terminal.
Disconnect the ground battery cable first when removing
a battery and connect it last when installing a battery.
• Do not short across the battery posts to check charge.
FIGURE 2-6 Short circuit, spark, or flame could cause battery
explosion.
Inspect the boom nose and hook block sheaves for proper
operation, excessive wear, and damage every 50 hours or • If applicable, maintain battery electrolyte at the proper
weekly. Inoperable, damaged and/or worn sheaves cause level. Check the electrolyte with a flashlight.
rapid deterioration of rope.
Engine
Fuel the crane only with the engine turned off. Do not smoke
while fueling the crane. Do not store flammable materials on SAMPLE
the crane.
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Be familiar with the location and use of the nearest fire
extinguisher.
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1
Be careful when checking the engine coolant level. The fluid
may be hot and under pressure. Shut down the engine and
allow the radiator time to cool before removing the radiator
7116-1A FIGURE 2-7
cap.
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Before transporting the crane on a road or highway, first
Shut down the engine and disconnect the battery before check state and local restrictions and regulations.
performing maintenance. If unable to do so for the task
required, keep hands clear of the engine fan and other Either the hook block may be reeved over the main boom
moving parts while performing maintenance. nose or the headache ball may be reeved over the main
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boom nose or auxiliary boom nose; the other must be
Be careful of hot surfaces and hot fluids when performing removed. If the hook block or headache ball remains reeved
maintenance on or around the engine. on the boom, it must be secured at the tie down on the carrier
Do not use ether to start the engine on cranes equipped with to prevent swinging.
intake manifold grid heaters. When using hookblock tie downs, excessive loading can be
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The engine can enter into a engine exhaust cleaning mode applied by pulling the cable too tight, particularly when
where the exhaust temperature can be high, ensure the reeved with multiple part lines. When the cable is hooked
exhaust is not pointed at materials that can melt, burn or into the hookblock tie down, the cable should be merely
explode. “snugged-up” with adequate slack provided at the center line
of sheave to anchor point. Do not draw cable taut. Care must
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TRANSPORTING THE CRANE be exercised anytime any crane function is being performed
while the cable is hooked into the hookblock tie down.
Before transporting the crane, check the suitability of the
proposed route with regard to the crane height, width, length, TRAVEL OPERATION
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and weight.
Only the crane operator shall occupy the crane when
Check load limits of bridges on the travel route and ensure traveling.
they are greater than the combined weight of the crane and
transporting vehicle. When traveling, the boom should be completely retracted
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and lowered to the travel position and the turntable pin swing
When loading or unloading the crane on a trailer or railroad lock, if equipped, should be engaged. If equipped with boom
car, use a ramp capable of supporting the weight of the rest, lower the boom into the boom rest and engage the
crane. turntable lock.
Ensure the crane is adequately secured to the transporting Strictly adhere to the guidelines and restrictions in the Load
vehicle. Chart for pick and carry operations.
Do not use the dead end lug (1, Figure 2-7) on the boom RT and Industrial cranes are manufactured with no axle
nose for tying down the boom during transport. Damage to suspension system. Traveling at high speeds, especially on
the lug and boom can result from usage as a tie down point. rough ground, may create a bouncing effect that can result in
loss of control. If bouncing occurs, reduce travel speed.
Death or serious injury could result from being crushed by
revolving tires.
Stunt driving and horse-play are strictly prohibited. Never WORK PRACTICES
allow anyone to hitch a ride or get on or off a moving crane.
Follow the instructions in this manual when preparing the Personal Considerations
crane for travel. Always adjust the seat and lock it in position, and fasten the
If using a boom dolly/trailer, thoroughly read and understand seat belt securely before you start the engine.
all the steps and safety precautions in this manual for setup Do not wear loose clothing or jewelry that can get caught on
and travel. controls or moving parts. Wear the protective clothing and
When driving the crane, ensure the cab is down, if equipped personal safety gear issued or called for by the job
with a tilting cab. conditions. Hard hat, safety shoes, ear protectors, reflective
clothing, safety goggles, and heavy gloves may be required.
Secure the hook block and other items before moving the
crane. Crane Access
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Watch clearances when traveling. Do not take a chance of
running into overhead or side obstructions.
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When moving in tight quarters, post a signal person to help
guard against collisions or bumping structures.
WARNING
Fall Hazard!
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Before traveling a crane, check suitability of proposed route
Working at elevated heights without using proper fall
with regard to crane height, width, and length.
protection can result in severe injury or death.
Never back up without the aid of a signal person to verify the Always use proper fall protection as required by local,
area behind the crane is clear of obstructions and/or state or federal regulations.
personnel.
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On cranes equipped with air-operated brakes, do not attempt You must take every precaution to ensure you do not slip
to move the crane until brake system air pressure is at and/or fall off the crane. Falling from any elevation could
operating level. result in serious injury or death.
Never exit or enter the crane cab or deck by any other means
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- Refer to the Operation Section for more detailed Do not use the top of the boom as a walkway.
information on traveling on slopes. Do not step on the outrigger beams or outrigger pads (floats)
- Driving across a slope is dangerous, as unexpected to enter or exit the crane.
changes in slope can cause tip over. Ascend or Use the hoist access platform (if equipped) when working in
descend slopes slowly and with caution. the hoist area.
- When operating on a downhill slope, reduce travel Wear shoes with a highly slip-resistant sole material. Clean
speed and downshift to a low gear to permit any mud or debris from shoes before entering the crane cab/
compression braking by the engine and aid the operator’s station or climbing onto the crane superstructure.
application of the service brakes. Excessive dirt and debris on the hand-holds, access steps,
or walking/working surfaces could cause a slipping accident. Sparks from the crane’s electrical system and/or engine
A shoe that is not clean might slip off a control pedal during exhaust can cause an explosion. Do not operate this crane
operation. in an area with flammable dust or vapors, unless good
ventilation has removed the hazard.
Do not allow ground personnel to store their personal
belongings (clothing, lunch boxes, water coolers, and the Carbon monoxide fumes from the engine exhaust can cause
like) on the crane. This practice will prevent ground suffocation in an enclosed area. Good ventilation is very
personnel from being crushed or electrocuted when they important when operating the crane.
attempt to access personal belongings stored on the crane.
Before actuating swing or any other crane function, sound
Job Preparation the horn and verify that all personnel are clear of rotating and
moving parts.
Before crane use:
Never operate the crane when darkness, fog, or other
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• Barricade the entire area where the crane is working and visibility restrictions make operation unsafe. Never operate a
keep all unnecessary personnel out of the work area. crane in thunderstorms or high winds.
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• Ensure that the crane is properly equipped including Always be aware of your working environment during
access steps, covers, doors, guards, and controls. operation of the crane. Avoid contacting any part of the crane
with external objects.
• Conduct a visual inspection for cracked welds, damaged
components, loose pins/bolts, and wire connections.
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Clear all personnel from the counterweight and
Any item or component that is found to be loose or superstructure area before removing the counterweight.
damaged (broken, chipped, cracked, worn-through, etc.)
must be repaired or replaced. Inspect for evidence of
improper maintenance (consult your Service Manual).
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• Check for proper functioning of all controls and operator
aids (for example, RCL).
• Check all braking (for example, wheel, hoist, and swing
brakes) and holding devices before operation.
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You must ensure that the outriggers and jack cylinders are
properly extended and set before performing any lifting
operations. On models equipped with outriggers that can be
pinned at the mid-extend position, the outriggers must also
be pinned when operating from the mid-extend position.
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warn personnel
Working
Operate the crane only from the operator’s seat. Do not
Operator shall be responsible for all operations under his/her reach in a window or door to operate any controls.
direct control. When safety of an operation is in doubt,
operator shall stop the crane’s functions in a controlled Operate the crane slowly and cautiously, looking carefully in
manner. Lift operations shall resume only after safety the direction of movement.
concerns have been addressed or the continuation of crane A good practice is to make a “dry run” without a load before
operations is directed by the lift supervisor. making the first lift. Become familiar with all factors peculiar
Know the location and function of all crane controls. to the job site.
Make sure all persons are away from the crane and the Ensure the hoist rope is properly routed on the hook block
Travel Select Lever is in the “N” (Neutral) position with the and boom nose and that all rope guards are in place.
Parking Brake engaged before starting the engine.
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Lift one load at a time. Do not lift two or more separately
rigged loads at one time, even if the loads are within the
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crane’s rated capacity.
Never leave the crane with a load suspended. Should it
become necessary to leave the crane, lower the load to the
ground and stop the engine before leaving the operator’s
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station.
Remember, all rigging equipment must be considered as
part of the load. Lifting capacities vary with working areas. If
applicable, permissible working areas are listed in the Load
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Chart. When swinging from one working area to another,
ensure Load Chart capacities are not exceeded. Know your
crane!
FIGURE 2-8 Stop the hook block from swinging when unhooking a load.
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Lifting Swinging rapidly can cause the load to swing out and
increase the load radius. Swing the load slowly. Swing with
Use enough parts of line for all lifts and check all lines, caution and keep the load lines vertical.
slings, and chains for correct attachment. To obtain
Look before swinging your crane. Even though the original
maximum lifting capacities, the hook block must be set up
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Never push or pull loads with the crane’s boom; never drag a
drum. When slings, ties, hooks, etc., are used, make certain
load.
they are correctly positioned and secured before raising or
lowering the loads. Do not subject crane to side loading. A side load can tip the
crane or cause it to fail structurally.
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Hand Signals
A single qualified signal person shall be used at all times
when:
• Working in the vicinity of power lines.
• The crane operator cannot clearly see the load at all
times.
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• Moving the crane in an area or direction in which the
operator cannot clearly see the path of travel.
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At all times use standardized hand signals - previously
agreed upon and completely understood by the operator and
signal person.
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If communication with the signal person is lost, crane
movement must be stopped until communications are
restored.
Keep your attention focused on the crane’s operation. If for
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some reason you must look in another direction, stop all
crane movement first.
Obey a signal to stop from anyone.
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Do not remove right side boom nose pins unless jib is • The boom should be retracted as far as is practical, the
properly pinned and secured on front and rear stowage crane configured in as stable a configuration as possible
brackets. (boom angle, superstructure orientation, jib angle, etc.)
• In high winds the boom and jibs should be lowered, or
secured. Changing weather conditions including but not
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limited to: wind, ice accumulation, precipitation, flooding,
DANGER lightning, etc. should be considered when determining
the location and configuration of a crane when it is to be
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Boom Extension Hazard!
left unattended.
To avoid death or serious injury, follow procedures in Load
Chart, safety, and operation manuals during erection,
stowage and use of jib. Install and secure all pins properly
SHUT-DOWN
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and control jib movement at all times. Use the following steps when shutting down the crane:
Do not remove all the pins from both front and rear stowage • Engage the parking brake.
brackets unless the jib is pinned to the right side of the boom • Fully retract and lower the boom.
nose.
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• Engage the swing lock pin or 360 degree swing lock (if
Properly inspect, maintain, and adjust jib and mounting. equipped).
When assembling and disassembling jib sections, use • Place crane function power switch to OFF (if equipped).
blocking to adequately support each section and to provide
• Place controls in neutral position.
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proper alignment.
Stay outside of jib sections and lattice work. • Shut down the engine and remove the ignition key.
Watch for falling or flying pins when they are being removed. • Chock the wheels, if not on outriggers.
• Lock the operator’s cab (if applicable) and install vandal
PARKING AND SECURING
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guards, if used.
Failure to comply with these instructions may cause death Don’t touch metal surfaces that could freeze you to them.
or serious injury
Clean the crane of all ice and snow.
When parking on a grade, apply the parking brake and chock Allow ample time for hydraulic oil to warm up.
the wheels.
In freezing weather, park the crane in an area where it
Section 3 of this manual provides instructions for parking and cannot become frozen to the ground. The drive line can be
securing a crane when it is to be left unattended. These damaged when attempting to free a frozen crane.
instructions are intended to allow the crane to be placed in
the most stable and secure position. However, Manitowoc If applicable to your crane, frequently check all air tanks for
recognizes that certain jobsite conditions may not permit the water in freezing weather.
boom and jib of a crane to be fully lowered to the ground. If applicable to your crane, always handle propane tanks
When a qualified person at a jobsite determines that it is not according to the supplier’s instructions.
practical to lower the boom to the ground, we recommend
the following additional instructions be followed: Never store flammable materials on the crane.
If cold weather starting aids are provided on your crane, use smoothly. Proper boom lubrication and wear pad adjustment
them. The use of aerosol spray or other types of starting is important to permit the boom sections to slide freely. Slow
fluids containing ether/volatiles can cause explosions or fire. movement of the boom may be undetected by the operator
unless a load is suspended for a long period of time. To
TEMPERATURE EFFECTS ON HOOK minimize the effects of thermal contraction or “Stick-slip” it is
BLOCKS recommended that the telescope control lever is activated
periodically in the extend position to mitigate the effects of
The following information applies to Gunnebo Johnston cooling oil.
crane hook blocks:
If a load and the boom is allowed to remain stationary for a
Never use a hook block in extreme tempera- period of time and the ambient temperature is cooler than the
tures...Sudden failure can occur. trapped oil temperature, the trapped oil in the cylinders will
Hook blocks shall not be heated above 82°C cool. The load will lower as the telescope cylinder(s) retracts
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(180°F). Hook Block Working Load Limit is valid allowing the boom to come in. Also, the boom angle will
between 82°C (180°F) and service temperature decrease as the lift cylinder(s) retracts causing an increase
given on the identification tag with normal lifting in radius and a decrease in load height.
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precautions.
This situation will also occur in reverse. If a crane is set up in
Additional lifting precautions are required below the the morning with cool oil and the daytime ambient
service temperature given on the identification tag temperature heats the oil, the cylinders will extend in similar
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because cold temperature begins to affect the hook proportions.
block material properties.
Table 2-8 and Table 2-9 have been prepared to assist you in
Lifting above 75% of the Working Load Limit (WLL), determining the approximate amount of retraction/extension
at temperatures between the service temperature that may be expected from a hydraulic cylinder as a result of
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given on the identification tag and -40°C (-40°F), change in the temperature of the hydraulic oil inside the
must (be) done at a slow and steady rate to avoid cylinder. The chart is for dry rod cylinders. If the cylinder rod
stress spikes common in normal hoisting dynamics. is filled with hydraulic oil, the contraction rate is somewhat
greater.
75% of the WLL must not be exceeded, when lifting
NOTE: Operators and service personnel must be aware
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cooled. This is a natural phenomena that happens to all telescope cylinders. (Service Bulletin 98-036
liquids. The coefficient of expansion for API Group 1 applies to TMS700 and Service Bulletin G06-005A
hydraulic oil is approximately 0.00077 cubic centimeters per applies to RT890 and RT9130.
cubic centimeter of volume for 1°C of temperature change
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Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74
20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
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40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
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55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96
3 3
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in /in / °F) X 12 in/ft
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Table 2-9 Boom Drift Chart (Cylinder length change in millimeters)
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(1/ °C)
Coef f . = 0.000774 M etri c
STROKE Temperature Change (°C)
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(m) 5 10 15 20 25 30 35 40 45 50 55
1.5 6 12 17 23 29 35 41 46 52 58 64
3 12 23 35 46 58 70 81 93 104 116 128
4.5 17 35 52 70 87 104 122 139 157 174 192
6 23 46 70 93 116 139 163 186 209 232 255
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13.5 52 104 157 209 261 313 366 418 470 522 575
15 58 116 174 232 290 348 406 464 522 581 639
16.5 64 128 192 255 319 383 447 511 575 639 702
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18 70 139 209 279 348 418 488 557 627 697 766
Length change in mm = Stroke (m) X Temperature Change ( °C) X Coef f . (1/ °C) X 1000 mm/m
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Figure 2-10 and step (2) (Fixed counterweight units only) is
in the travel configuration. Remove pins from hand rail and representation of your crane and are to be used for reference
only.
rotate it down into the travel position, reinstall pins. Pull the
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step locking pin out, slide the step in to the travel position
and release the lock pin.
WARNING
Overload Hazard!
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To avoid an accident caused by overload damage to
your crane:
• Perform the inspections outlined in this publication
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for overloads up to 50%.
• Stop operating the crane and contact Manitowoc
Crane Care immediately for overloads of 50% and
higher.
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1
7649-14
FIGURE 2-11
Boom Inspection
1
1
2
9, 10
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1 8
3, 4
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1 Sheaves Inspect all for damage.
Luffing
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2 Mechanism/ Inspect for damage/leaks.
Cylinder
Collar-wear
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3 Inspect all for damage.
pads
4 Collar-welds Inspect all for cracks.
Telescopic Inspect for bent or twisted sections. Check the boom
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Sections for straightness.
Lift Cylinder
6 Inspect for bends or cracked welds.
Head Area
Turret-Base
7 Inspect for cracked welds.
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Section
Locking Area
8 Inspect for elongated holes.
(Pin Booms)
9 Welds Inspect for cracks.
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Superstructure Inspection
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5 4
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9, 10
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Turntable See topic in Swing section of
2 Check bolts for proper torque.
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Bearing Service Manual.
See topic in Introduction section
3 Wire Rope Inspect all for damage.
of Service Manual.
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4 Hoist/Drums Inspect each for damage.
5 Hoist Brakes Brakes must hold rated line pull.
Bearing Main
6 Boom Pivot Inspect for deformation, cracked welds.
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Pin
Lift Cylinder-
7 Inspect pin and welds.
lower mount
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Carrier Inspection
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3
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2 5, 6
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Illustration is for reference only, it
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Outrigger
3 Inspect for deformation and cracked welds.
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Beams
Outrigger
4 Inspect for deformation and cracked welds.
Boxes
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5 Welds Inspect for cracks.
Inspect for cracked paint which could indicate twisted,
6 Paint
stretched, or compressed members.
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SECTION 3
OPERATING CONTROLS AND PROCEDURES
SECTION CONTENTS
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . 3-2 Low Steer Pressure (Optional on CE Units) . . . . 3-10
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Left Turn Signal Indicator. . . . . . . . . . . . . . . . . . . 3-10
Turn Signal Lever and Windshield Wiper/Washer/ Low Brake Pressure . . . . . . . . . . . . . . . . . . . . . . 3-10
Headlight /Horn Controls. . . . . . . . . . . . . . . . . . . . 3-3 Electronic Module Indicator . . . . . . . . . . . . . . . . . 3-10
Steering Column Adjustment Lever . . . . . . . . . . . 3-3 Electronic System Diagnostic . . . . . . . . . . . . . . . 3-10
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Park Brake Control Switch . . . . . . . . . . . . . . . . . . 3-3 LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Headlights Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Engine Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
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Drive Axle Selector Switch . . . . . . . . . . . . . . . . . . 3-3 Engine Warning . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Hazard Lights Switch . . . . . . . . . . . . . . . . . . . . . . 3-3 Exhaust System Cleaning Indicator. . . . . . . . . . . 3-11
Engine Diagnostic and Engine Speed Control Right Turn Signal Indicator . . . . . . . . . . . . . . . . . 3-12
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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Inhibit Exhaust System Cleaning Indicator . . . . . 3-12
Ignition Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Diesel Exhaust Fluid Indicator . . . . . . . . . . . . . . . 3-12
Transmission Shift Lever . . . . . . . . . . . . . . . . . . . 3-4 High Exhaust System Temperature Indicator . . . 3-12
Cab Overhead Controls . . . . . . . . . . . . . . . . . . . . . 3-5 Engine Wait-to-Start Indicator . . . . . . . . . . . . . . . 3-12
Skylight Window Latch . . . . . . . . . . . . . . . . . . . . . 3-5 Four-Wheel Drive Engaged Indicator . . . . . . . . . 3-12
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Skylight Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Axle Differential Locked Indicator . . . . . . . . . . . . 3-12
Skylight Sunscreen . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Rear Wheels Not Centered Indicator. . . . . . . . . . 3-12
Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Engine Coolant Temperature Gauge. . . . . . . . . . 3-12
Cab Circulating Fan . . . . . . . . . . . . . . . . . . . . . . . 3-5 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
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Right Side Window Latch . . . . . . . . . . . . . . . . . . . 3-5 Low Fuel Level Indicator . . . . . . . . . . . . . . . . . . . 3-13
Overhead Control Panel. . . . . . . . . . . . . . . . . . . . . 3-6 Battery Charge Indicator . . . . . . . . . . . . . . . . . . . 3-13
Heater/Air Conditioner Fan Switch . . . . . . . . . . . . 3-6 Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . 3-6 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Air Conditioner Switch. . . . . . . . . . . . . . . . . . . . . . 3-6 DEF Tank Level/Gauge . . . . . . . . . . . . . . . . . . . . 3-13
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Skylight Wiper Switch . . . . . . . . . . . . . . . . . . . . . . 3-6 Control Seat Assembly (Single Axis) . . . . . . . . . 3-14
Panel Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . 3-6 Main Hoist Joystick (Single Axis). . . . . . . . . . . . . 3-14
Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Boom Lift Joystick (Single Axis). . . . . . . . . . . . . . 3-14
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Boom Lights Switch (Optional) . . . . . . . . . . . . . . . 3-7 Boom Lift and Main Hoist Joystick
Crane Function Power Switch. . . . . . . . . . . . . . . . 3-7 (Dual Axis Option) . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Hoist Rotation Indicator Display . . . . . . . . . . . . . . 3-7 Main Hoist Speed Selector Switch. . . . . . . . . . . . 3-14
Exhaust System Cleaning Switch . . . . . . . . . . . . . 3-7 Telescope or Auxiliary Hoist Joystick
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Transmission Oil Temperature Gauge . . . . . . . . 3-17
Turntable Pin Swing Lock Control . . . . . . . . . . . . 3-17 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . 3-21
12V Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Pre-Starting Checks . . . . . . . . . . . . . . . . . . . . . . . 3-21
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Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . 3-18 Cold Weather Operation . . . . . . . . . . . . . . . . . . . 3-22
Bubble Level Indicator. . . . . . . . . . . . . . . . . . . . . 3-18 Crane Warm-up Procedures . . . . . . . . . . . . . . . . . 3-24
Hoist Third Wrap Indicator Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
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(Optional—Standard on CE) . . . . . . . . . . . . . . . . 3-18 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Cold Weather Indicator (Optional). . . . . . . . . . . . 3-18 Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Ambient Temperature LED Indicator. . . . . . . . . . 3-18 Swing Drive and Turntable Bearing . . . . . . . . . . . 3-25
Boom Not Synchronized Indicator. . . . . . . . . . . . 3-18 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
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Outrigger Control . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Hydraulic Oil System . . . . . . . . . . . . . . . . . . . . . . 3-25
Foot Pedal Controls . . . . . . . . . . . . . . . . . . . . . . . 3-19 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
360° Swing Lock Pedal . . . . . . . . . . . . . . . . . . . . 3-19 Transporting the Crane . . . . . . . . . . . . . . . . . . . . 3-27
Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . 3-19 Crane Travel Operation . . . . . . . . . . . . . . . . . . . . 3-27
General Crane Operation. . . . . . . . . . . . . . . . . . . 3-35
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2. Outrigger Control 1
STEERING COLUMN Pushing the ring button in the end of the knob energizes the
windshield washer pump to spray washer fluid on the
The steering column assembly in Figure 3-2 is a pedestal windshield. Positioning the knob to I operates the wiper at
style tilt and telescoping steering column. It has the ability to low speed and positioning the knob to II operates the wiper
tilt forward 30° or be raised vertically approximately 2.5 at high speed. Positioning the knob to O turns the wiper
inches. It also includes the ignition switch and the CAN bus motor off and automatically returns the wiper to the parked
gauge display (11) (Figure 3-2). position.
Pushing the small button on the end of the lever sounds the
horn.
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approximately 30° and raised approximately 2.5 inches.
Rotate the steering column adjustment lever (2) (Figure 3-2)
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counterclockwise to release the steering column for
adjustments; rotate the steering column adjustment lever (2)
(Figure 3-2) clockwise to lock the steering column in place.
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2
Park Brake Control Switch
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3
7 The Park Brake Control Switch (3) (Figure 3-2) is located on
5 8
4 6 the front of the steering column. This two-position rocker
switch (ON/OFF) is used to apply and release the parking
7649-1
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FIGURE 3-2 brake on the drive line. The red Park Brake Indicator light on
the steering column is illuminated when the pressure switch
Figure 3-2 Item Numbers in the brake release system is activated and the brake is
Item Description applied.
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4 Headlights Switch
front, rear, and side of the crane. When the switch is in the
5 Drive Axle Selector Switch ON position, the steering column and switch lights are
6 Hazard Lights Switch illuminated.
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Engine Diagnostic and Engine Speed bottom of the switch once to return to low engine idle. If the
Control Switches engine speed is below the maximum RPM setting, pressing
and holding the top of the switch will cause the engine RPM
Two engine diagnostic and speed control switches (Engine to slowly increase; release the switch when the desired RPM
Diagnostic/Speed Control and Increment/Decrement) are is attained. If the engine speed is above the minimum RPM
located on the front of the steering column. setting, pressing and holding the bottom of the switch will
cause the engine RPM to slowly decrease; release the
Engine Diagnostic/Speed Control Switch switch when the desired RPM is attained.
T h e E n g i n e D i a g n o s t i c / Sp e e d C o n t r o l S w i t c h ( 7 )
(Figure 3-2) is a two position maintained ON/OFF rocker Ignition Switch
switch used to access the engine fault codes or enable the The Ignition Switch (9) is located on the right side of the
control of the low engine idle and engine RPM functions. steering column and under the transmission shift lever(10).
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Diagnostic function — With the Ignition Switch in the RUN The switch is key-operated and has four positions: ACC [3],
position and the engine off, press the top of the Engine OFF [0], RUN [1], and START [2]. In the OFF position, all
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Diagnostic/Speed Control Switch to view the engine fault electrical power is off except for the lights controlled by the
codes on the steering column display. If there is more than Headlights Switch, turn/hazard/stop lights, dome light and
one active engine fault code, use the Increment/Decrement work light. Positioning the switch to ACC energizes all
Switch (8) (Figure 3-2) to toggle forward and backward electrical components except for the start solenoid and
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through the fault codes. If there are no engine fault codes, engine ECM. Positioning the switch to RUN is the same as
zeros will be shown in the steering column display. ACC, but the ignition circuit is also energized. Positioning the
Engine low idle function — With the engine running and the switch to START energizes the start relay, which in turn
top of the Engine Diagnostic/Speed Control Switch pressed, energizes the cranking motor solenoid and cranks the
the engine low idle is adjusted using the Increment/ engine for starting. The switch is spring returned from
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Decrement Switch (8) (Figure 3-2). START to RUN. To shut down the engine, position the switch
to OFF.
Engine RPM function — With the engine running and the
bottom of the Engine Diagnostic/Speed Control Switch The Ignition switch has a mechanical anti-restart built into it.
pressed, the engine RPM is adjusted using the Increment/ If the engine does not start after the first attempt, the key
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Decrement Switch (8) (Figure 3-2). switch must go to the OFF position and then back to START
in order to try and start the engine another time.
Increment/Decrement Switch
Transmission Shift Lever
The Increment/Decrement Switch (8) (Figure 3-2) is a three
position momentary rocker switch with center maintained
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CAB OVERHEAD CONTROLS rear to open. To close slide the window forward until the latch
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engages.
1 2 Skylight Wiper
The Skylight Wiper (2, Figure 3-3) is controlled by the
3
Skylight Wiper Switch, (4, Figure 3-4), and operated by the
Wiper Motor.
Skylight Sunscreen
The Skylight Sunscreen (3, Figure 3-3) is used to diminish
direct sunlight. The sunscreen is self retracting and can be
set to screen all the light or adjusted reward by moving it into
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the notches provided.
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6
4
Dome Light
The Cab Dome Light (4, Figure 3-3) is on the right rear
5 7 corner of the cab overhead console and provides illumination
in the cab. The dome light is controlled by a switch on the
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8126
FIGURE 3-3
light.
Item Description
Cab Circulating Fan
1 Skylight Window Latch
The Cab Circulating Fan (5, Figure 3-3) is located on the left
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2 Skylight Wiper front side of the cab, above the window frame. A swivel
3 Skylight Sunscreen allows the fan to be rotated and a switch on the fan base
controls the fan. The switch has a high, low and off positions.
4 Dome Light
5 Cab Circulating Fan Right Side Window Latch
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6 Window Latch The window on the right side of the cab can be opened.
7 Overhead Control Panel Squeeze latch (6, Figure 3-3) to release the window and
slide forward. To close slide the window rearward until the
Skylight Window Latch latch engages.
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6 8 11 13 15
1 2 3 4 5 7 9 10 12 14 16 17
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8126-1
FIGURE 3-4
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Figure 3-4 Item Numbers Heater Control Switch
Item Description The Heater Control Switch (2, Figure 3-4) controls intensity
of heating temperature. Turn the switch to the right (clock-
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1 Heater/Air Conditioner Fan Switch
wise) to open the valve for heat. (Heat comes from heated
2 Heater Control Switch fluid going through the heater coil.) Turn the switch to the left
3 Air Conditioning Switch (counterclockwise) to close the valve to stop fluid flow and
minimize heat.
4 Skylight Wiper Switch
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Boom Lights Switch (Optional) Within 5 seconds the engine should rev up to 1000 to 1400
rpm. The engine will continue to run at this speed for up to 45
The Boom Lights Switch (7) (Figure 3-4) is located on the minutes.
side display panel. This two-position rocker switch (ON/OFF)
controls operation of the boom flood lights. Press the top of Pressing the brake or throttle pedal during cleaning or
the switch to turn on the boom lights, press the bottom of the activating the Inhibit Exhaust System Cleaning Switch will
switch to turn the lights off. interrupt the cleaning process.
Make sure the crane and surrounding area are monitored
Crane Function Power Switch during manual cleaning. If any unsafe condition occurs, shut
The Crane Function Power Switch (8) (Figure 3-4) is located off the engine immediately.
on the side display panel. This two-position (ON/OFF) rocker During this period the sound of the engine may change.
switch permits the operator to disconnect power from the When cleaning is complete the engine will return to its
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crane functions controlled by the hydraulic remote normal idle speed.
controllers on the armrests. Positioning the switch to OFF
prevents inadvertent operation of functions due to bumping
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the controllers while roading or any other operation.
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The display is located in the front overhead panel Figure 3-9.
Refer to Hoist Rotation Indicator Display, page 3-7 for more
information.
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Exhaust System Cleaning Switch 3
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WARNING
Fire or Burn Hazard!
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1 FIGURE 3-5
The Engine Exhaust System Cleaning Switch (9)
(Figure 3-4) is located on the right side of the overhead Boom Section 1/Section 2 Selector Switch
control panel. This switch is a three position switch, INHIBIT and Indicator
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• Inhibit Cleaning (7649-11) When the Boom Manual/Automatic Mode Selector Switch
(12) is positioned to manual mode, the Boom Section 1/
To manually clean, set the crane parking brake, the crane Section 2 Selector Switch (10) is used to select the
transmission must be in neutral and have all pedals section(s) of the boom that will telescope in and out when
released. actuated. When the switch (10) is positioned to Section 2
Set up a safe area around the crane’s exhaust; remove tools, (top of switch is pressed), sections 2, 3, and 4 can be
rags, grease or any debris from the engine exhaust area. As extended and retracted; when the switch is positioned to
a warning, the light (1, Figure 3-5) below the exhaust pipe (2, Section 1 (bottom of switch is pressed), section 1 can be
Figure 3-5) will flash during system cleaning. extended and retracted. When not operating in the manual
mode, the Boom Section 1/Section 2 Selector Switch (10)
With the engine idling push the Exhaust System Cleaning should be in the OFF (center) position.
Switch (9) to initiate cleaning.
When operating in the manual mode, the Boom Section 1/ switch (14) is a two position rocker type switch that is used to
Section 2 Indicator (11) (Figure 3-4) will indicate which boom change the sequence in which the boom sections extend
section has been activated by the Boom Section 1/Section 2 and retract when operating in the Automatic mode.
Selector Switch (10).
With the Boom Manual/Automatic Mode Selector Switch (12)
Boom Manual/Automatic Mode Selector (Figure 3-4) positioned to automatic mode and the Boom A/B
Mode Selector Switch (14) positioned to A mode (top of
Switch and Indicator switch is pressed), the boom control system, when extending
The Boom Manual/Automatic Mode Selector Switch (12) the boom, will fully extend Sections 2, 3, and 4 before
(Figure 3-4) and Indicator (13) are located on the overhead extending Section 1; and when retracting the boom, the
control panel. The switch (12) is a two-position rocker type control system will fully retract Section 1 before retracting
switch labeled AUTO (Automatic) and MAN (Manual). Sections 2, 3, 4. Conversely, when the Boom A/B Mode
Selector Switch is positioned to B mode, the boom control
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Normal crane operation is performed with the Boom Manual/ system, when extending the boom, will fully extend Section 1
Automatic Mode Selector Switch (12) positioned to the Auto before extending Sections 2, 3, and 4; and when retracting
Mode (bottom of switch is pressed), which causes the boom the boom, the control system will fully retract Sections 2, 3, 4
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sections, when actuated, to extend and retract in a before retracting Section 1.
predetermined sequence based on the position of the Boom
A/B Mode Selector Switch (14) (Figure 3-4). When the Boom Switching between A and B modes can only be done when
Manual/Automatic Mode Selector Switch (12) is positioned the boom sections are fully retracted or fully extended.
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to Auto Mode, the Boom Manual/Automatic Mode Indicator Changing modes in any other boom configuration will cause
will indicate Auto Mode. the RCL to lockout the boom telescope functions and turn on
the Boom Not Synchronized Indicator.
When the Boom Manual/Automatic Selector Switch (12) is
positioned to Manual Mode (top of switch is pressed), the The Boom A/B Mode Indicator (15) is labeled A and B and
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Boom Manual/Automatic Mode Indicator (13) will indicate consists of two LEDs; one for A mode and one for B mode.
Manual Mode and the operator can control the sequence in Dependent upon which position the Boom A/B Mode
which the boom sections extend and retract by way of the Selector Switch is in, the respective LED will illuminate.
Boom Section 1/Section 2 Selector Switch (10). This manual
mode of operation is necessary when servicing the boom Boom Recovery Mode Switch and Indicator
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and for the subsequent boom re-synchronization that is The Boom Recovery Mode Switch (16) (Figure 3-4) and
needed to return the control system from the Manual mode Indicator (17) are located on the overhead control panel. The
to the Automatic mode. Also, during Automatic mode switch (16) is a two position rocker type switch that has an
operation, if the rated capacity limiter (RCL) determines that integral lock to prevent accidental activation. The Recovery
the boom is not synchronized, manual control of the boom Mode Switch overrides the boom control system and allows
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sections is again needed for boom/control system re- the boom to be recovered (retracted) in the event the boom
synchronization. telescope function stops working due to a sensor failure or
loss of communication with the rated capacity limiter (RCL).
Boom A/B Mode Selector Switch and The indicator (17) will flash if a failure occurs. Refer to
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Indicator Retracting the Boom Using the Boom Recovery Mode, page
3-39 to recover the boom if there is a failure in the boom
The Boom A/B Mode Selector Switch (14) (Figure 3-4) and
control system.
Indicator (15) are located on the overhead control panel. The
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8 10 12 13 16
9 32 15 18
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31 30
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29 27 26
FIGURE 3-6
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Item Description turn off the engine and try to find the cause of the high
hydraulic oil temperature.
28 Battery Charge Indicator
29 Voltmeter Transmission Warning
30 Tachometer The Transmission Warning Indicator (6) (Figure 3-6) is
located in the steering column gauge display. It illuminates
31 Push Button Switch (not used)
red during high transmission oil temperature conditions. A
32 DEF Level/Gauge warning buzzer will also sound.
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red when the Turntable Swing Motor Swing Brake is the hydraulic pressure is low. A warning buzzer will also
engaged preventing the rotation of the crane superstructure. sound.
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Parking Brake Engaged Left Turn Signal Indicator
The Parking Brake Engaged Indicator (2) (Figure 3-6) is The Left Turn Signal Indicator (8) (Figure 3-6) is located in
the steering column gauge display. It is a green arrow light
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located in the steering column gauge display. It illuminates
red when the crane parking brake is engaged. that flashes when the turn signal lever is pushed down or the
HAZARD light switch is positioned to ON.
Light Malfunction
Low Brake Pressure
The Light Malfunction Indicator (3) (Figure 3-6) is located in
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the steering column gauge display. It illuminates amber when The Low Brake Pressure Indicator (9) (Figure 3-6) is located
the crane headlights are malfunctioning. in the steering column gauge display. It illuminates red when
the pressure in the dual accumulator charge valve falls
Emergency Stop below normal operating requirements. A warning buzzer will
also sound.
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Hydraulic Oil High Temperature modules are off-line and not communicating with the system,
the indicator illuminates red.
T h e H y d r a u l i c O i l H i g h Te m p e r a t u r e I n d i c a t o r ( 5 )
(Figure 3-6) is located in the steering column gauge display. Electronic System Diagnostic
It illuminates red when the hydraulic oil temperature exceeds
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93°C (200°F); a warning buzzer will also sound. When this The Electronic System Diagnostic Indicator (11) (Figure 3-6)
indicator illuminates, set down the load as soon as possible, is located in the steering column gauge display. The indicator
is a red light used for troubleshooting the CANbus system.
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LCD Display If this indicator light illuminates, note the fault code and see
Engine Operator Manual.
The LCD Display(12) (Figure 3-6) is located in the steering
column gauge display. The display shows the transmission The Engine Warning Indicator may also illuminate with the
gear being used, fault codes, DEF tank level, and master Diesel Oxidation Catalyst Indicator or Diesel Exhaust Fluid
software version. Indicator.
If an active engine fault code is present, the display will show Exhaust System Cleaning Indicator
the code when the Ignition Switch is in the RUN position and
the engine is off. The display will show the master software The Exhaust System Cleaning Indicator (15) (Figure 3-6) is
version when the Ignition Switch is in the ACC position. located in the steering column gauge display. This indicator
illuminates amber when the exhaust system is getting filled
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with soot and needs to be cleaned out.
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When the Exhaust System Cleaning Indicator illuminates or
flashes, start cleaning process.
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3 1 The indicator will be lit continuously during the early stages
of clogging. If the system continues to clog, the lamp will
begin to flash and slight engine derate will occur.
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If even more clogging occurs, the engine warning light (14)
will illuminate in addition to the Exhaust System Cleaning
Indicator (15) and severe engine derate will occur.
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WARNING
Extreme Heat Hazard!
7649-35 FIGURE 3-7
During the cleaning process the exhaust becomes very
hot. Do not park the vehicle near objects that are
Figure 3-7 Item Numbers
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flammable.
Item Description Use caution near the exhaust tailpipe as it will also
1 Engine Fault Code, Master Software Version become very hot.
2 Transmission Gear Selected The cleaning process can take place in three different
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buzzer will also sound. The resulting chemical reaction raises exhaust gas
temperatures high enough to oxidize the hydrocarbon from
If this indicator light illuminates, note the fault code, shut the the filter and burn off any accumulation of diesel exhaust fluid
engine off and refer to the Engine Operator Manual. from the dosing module. This is all done without any operator
intervention.
Engine Warning
Manual: Manual or stationary cleaning is the same as active
The Engine Warning Indicator (14) (Figure 3-6) is located in cleaning but takes place while the equipment is not being
the steering column gauge display. It illuminates amber when operated. It offers the equipment operator the option, if
a signal is sent from the engine ECM. needed, of performing cleaning outside the normal duty
cycle.
Right Turn Signal Indicator amber for a period of time when the ignition switch is in the
ON position. The engine should not be cranked until the
The Right Turn Signal Indicator (16) (Figure 3-6) is located in Wait-to-Start light turns off. This light is controlled by the
the steering column gauge display. It is a green arrow light engine ECM.
that flashes when the turn signal lever is pushed up or the
Hazard Light switch is positioned to ON. Four-Wheel Drive Engaged Indicator
Inhibit Exhaust System Cleaning Indicator The Four-Wheel Drive Indicator (21) (Figure 3-6) is located
in the steering column gauge display. It illuminates amber
The Inhibit Exhaust System Cleaning Indicator (17) when the Drive Axle Selector Switch (5) (Figure 3-2) is in the
(Figure 3-6) is located in the steering column gauge display. four-wheel low position. This indicator will also blink if the
When the Exhaust System Cleaning Switch (9) (Figure 3-4) crane is shifted between two-wheel high and four-wheel low
is in the inhibit cleaning position, this amber indicator is and the brake pedal is not depressed and the transmission is
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illuminated and active and manual cleaning is prevented. not in neutral.
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The Diesel Exhaust Fluid (DEF) Indicator (18) (Figure 3-6) is The Axle Differential Locked Indicator (22) (Figure 3-6) is
located in the steering column gauge display. The indicator located in the steering column gauge display. This indicator
has four different stages which will be triggered by the fluid illuminates amber after the Differential Lock Switch (10)
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level sensor in the DEF tank: (Figure 3-8) is pressed to the LOCK position and the carrier
Low Tank - First warning to the operator is that the reducing differential lock switches located on each axle are closed.
agent in the tank is low. The DEF Indicator (18) will be lit When in the LOCK position there is no differential action
continuously. between the wheels.
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Derate - The DEF Indicator (18) will start to flash as a Rear Wheels Not Centered Indicator
warning to the operator that a derate will be activated if the
reducing agent in the DEF tank is not refilled. The Rear Wheels Not Centered Indicator (23) (Figure 3-6) is
located in the steering column gauge display. The indicator is
Low Level Inducement - The DEF Indicator (18) will flash and an amber light that will illuminate any time the rear wheels
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the engine warning indicator (14) will be lit continuously. are not centered.
Derate will be activated at this stage.
Severe Inducement - Once the DEF (18) tank is empty, the Engine Coolant Temperature Gauge
crane operation will be restricted. The DEF Indicator (18) will The Engine Coolant Temperature (water temp) Gauge (25)
flash and the Stop Engine Indicator (13) is solid red. (Figure 3-6) is located in the steering column gauge display.
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display.
Fuel Gauge
During exhaust system cleaning it is possible for the engine
exhaust to reach temperatures exceeding 650°C (1200°F). The Fuel Gauge (26) (Figure 3-6) is located in the steering
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The HEST indicator will illuminate red to warn the operator column gauge display. The gauge indicates the quantity of
when temperatures reach 675°C (1247°F) and will stay on fuel in the fuel tank and has a scale calibrated from empty (0)
until the temperatures falls below 625°C (1157°F). to full (4/4). The fuel gauge receives a signal from a sending
unit in the fuel tank.
Warning lights near the tailpipe will flash during cleaning
when high exhaust temperatures exist.
For more information on the exhaust system cleaning CAUTION
process, refer to Exhaust System Cleaning Indicator, page 3- Engine Damage!
11 Ultra low sulfur diesel fuel required in Tier 4 engines.
Engine Wait-to-Start Indicator If “Ultra Low Sulfur” fuel is not used in engines that require
it, the Cummins warranty will be void and the engine
The Engine Wait-to-Start Indicator (20) (Figure 3-6) is performance will quickly deteriorate and may stop
located in the steering column gauge display. It illuminates running.
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there is no alternator charge signal present.
column gauge display. The tachometer registers engine
If the engine is running and the Battery Charge Indicator RPM and is calibrated in RPM x 100 with a range of zero [0]
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illuminates, investigate possible alternator, alternator fuse, or to 35. The tachometer receives a signal from the engine
alternator wiring, or drive belt problems. ECM.
When the engine is not running and the Ignition Switch is in DEF Tank Level/Gauge
the ACC or RUN position, the Battery Charge Indicator turns
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on to indicate the batteries are being drained and not being The DEF Tank Level/Gauge (32) (Figure 3-6) is located in
charged. the steering column gauge display. The DEF Tank Level/
Gauge displays the percent of diesel exhaust fluid remaining
in the tank along with a bar gauge showing the amount of
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fluid in the tank.
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7649-4
FIGURE 3-8
Item Description The Main Hoist Joystick(1) (Figure 3-8) is located on the
1 Main Hoist Joystick, Raise/ Lower right armrest. The joystick, when pushed forward, lowers the
cable; when pulled back, it raises the cable.
2 Boom Lift Joystick
3 Main Hoist Speed Switch Boom Lift Joystick (Single Axis)
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4 Boom In/Out (Auxiliary Hoist Raise/Lower) The Boom Lift Joystick (2) (Figure 3-8) is located on the right
armrest. The joystick, when pushed forward, lowers the
5 Swing Joystick, Left/Right boom; when pulled back, it raises the boom.
6 Auxiliary Hoist Speed Switch
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main hoist functions and de-energizes the Main Hoist High hoist. When equipped with an auxiliary hoist, the joystick
Speed Solenoid, resulting in low line speeds. controls the swing and auxiliary hoist functions and the
telescope functions are controlled through a foot pedal.
Telescope or Auxiliary Hoist Joystick (Single
If not equipped with an auxiliary hoist, pushing the joystick to
Axis) the left or right actuates a control valve through hydraulic
The Telescope or Auxiliary Hoist (TELE or AUX) Joystick (4) pilot pressure to provide 360 degree continuous rotation in
(Figure 3-8) is located on the left armrest. The joystick the desired direction. Pushing the joystick forward actuates
controls the telescope functions when the crane is not the control valve to telescope the boom out and pulling the
equipped with an auxiliary hoist. Push the joystick forward to joystick back actuates the boom to telescope in.
telescope the boom out, or pull the joystick back to telescope If equipped with an auxiliary hoist, pushing the joystick
boom in. forward actuates the control valve to let out hoist cable and
pulling the joystick back reels the cable in. Moving the
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When equipped with an auxiliary hoist, the joystick controls
the auxiliary hoist functions and the telescope functions are joystick in a diagonal direction actuates the two functions
controlled through a foot pedal. Push the joystick forward to simultaneously.
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let out the hoist cable or pull the joystick back to reel the
cable in. Auxiliary Hoist Speed Selector Switch
(Optional)
Swing Joystick (Single Axis)
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The Auxiliary Hoist Speed Selector Switch (6) (Figure 3-8) is
a three positioned maintained switch (HIGH/OFF/LOW) that
is located on the left armrest. Positioning the switch to HIGH
position allows auxiliary hoist functions and energizes the
DANGER Auxiliary Hoist High Speed Solenoid, resulting in high line
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Crushing Hazard! speeds. Positioning the switch to the center OFF position will
Death or serious injury could result from being crushed by prevent hoisting. Positioning the switch to the LOW position
moving machinery. allows auxiliary hoist functions and de-energizes the
Auxiliary Hoist High Speed Solenoid, resulting in low line
Before actuating swing or any other function, sound horn speeds.
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Hoist Joystick (Dual Axis Option—Not centered the Rear Wheels Not Centered light on the steering
column illuminates. Releasing the switch causes it to return
Shown) to the center off position.
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To straighten the rear wheels press the switch until the Rear
Wheels Not Centered indicator light goes off.
DANGER Swing Brake Control Switch
Crushing Hazard!
The Swing Brake Control Switch (8) (Figure 3-8) is located
Death or serious injury could result from being crushed by
on the left arm rest. This two-position rocker switch (ON/
moving machinery.
OFF) is used to control a hydraulic valve that directs a
Before actuating swing or any other function, sound horn regulated flow of pressure to and from the swing brake.
and verify that all personnel are clear of rotating and Positioning the switch to ON will apply the swing brake and
moving parts. positioning the switch to OFF will release the swing brake.
When the switch is in the ON position, the red indicator light
The Swing and Telescope or Auxiliary Hoist (SWING/TELE on the steering column is illuminated. The switch has a lock
or SWING/AUX) Joystick is located on the end of the left to prevent accidental activation.
armrest. The joystick controls the swing and telescope
functions when the crane is not equipped with an auxiliary
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positioned to UNLOCK, there is normal differential action
between the wheels all the time. The amber indicator on the 2 4
steering column is illuminated when the switch in each axle
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is activated.
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Use the Cab Door Release Lever (10) (Figure 3-8) to open 8425
and close the cab door from inside the cab.
FIGURE 3-9
(16) (Figure 3-8) is located in the cab under the driver’s seat.
The vents (12) are part of the climate control unit and can be
adjusted to direct the flow of air.
Hydraulic Boost Switch
Seat Slide Lever
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SIDE CONTROL PANEL Rated Capacity Limiter (RCL) and Work Area
Definition System (WADS) Control Panel
The RCL and WADS Control Panel (1) (Figure 3-10) is
located on the right side of the cab. It maintains the controls
and indicators for the crane’s Rated Capacity Limiter System
and Work Area Definition System. Refer to the RCL Manual
1 for detailed information.
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position (right) to disengage the RCL controls. Release the
13 key to allow the RCL controls to re-engage.
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The RCL will be bypassed only as long as the switch is in the
2 ON position.
Turning the key switch to the ON position re-engages the
boom down, telescope out and hoist up functions, which are
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disabled when an overload condition is sensed by the Rated
7 Capacity Limiter (RCL). It is important to read and
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understand the RCL Override Warning information in the
RCL Operator Manual before using the RCL Bypass switch
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(2) or the RCL on/off switch.
8
Emergency Stop Switch
The crane Emergency Stop Switch (3) (Figure 3-10) is
9 located on the cab console and is used to shut down the
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6 Turntable Pin Swing Lock Control Turntable Pin Swing Lock Control
7 12 Volt Receptacle T h e Tu r n ta b l e P i n S w i n g L o c k C o n t r o l H a n d l e ( 6 )
(Figure 3-10) is located on the side control panel. The
8 Diagnostic Connector purpose of the pin swing lock is to lock the superstructure in
9 Bubble Level Indicator position directly over the front for pick and carry loads.
10 3rd Wrap Indicator (optional) When the control handle is pushed in and the superstructure
11 Cold Weather Indicator (optional) is directly over the front, the swing lock pin drops into the
socket on the carrier frame, locking the superstructure in
Ambient Temperature LED Indicator place.
12
(optional)
13 Boom Not Synchronized Indicator
When the control handle is pulled out, the pin is pulled out of along with lockout override, will still be operational to lower
the socket, unlocking the superstructure. the load.
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This 12 volt accessory outlet (7) (Figure 3-10) is located on synchronize the boom with the RCL.
the lower part of the control panel and is designed to mate
with most 12 volt adapter plugs.
OUTRIGGER CONTROL
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Diagnostic Connector .
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lower part of the front control panel. It is used for servicing
the crane’s electrical system.
A laptop computer with a nine pin cable connector and the
appropriate service software are required. Contact your local 1
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Grove distributor or Manitowoc Crane Care for assistance.
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The optional Cold Weather Indicator (11) (Figure 3-10) is
located on the right side console. The indicator comes on
when ambient temperature is at or below -29°C (-20°F). It 5
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Extend/Retract Switch release the swing lock, pull up on the 360° Swing Lock
The Extend/Retract Switch (6,7 Figure 3-11) is located on Release Lever (2).
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the side of the Outrigger Control Box and is used in
conjunction with the Outrigger Selector Switches (2,3,4,5
Swing Brake Pedal
Figure 3-11) to control the outrigger functions. The Swing Brake Pedal (3) (Figure 3-12) is located on the
left side of the cab floor. The swing brake pedal is used to
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Outrigger Selector Switches
actuate the swing brake to slow or stop swing motion.
There are four Outrigger Selector Switches (2,3,4,5 Braking is proportional to pedal depression. With the pedal
Figure 3-11) on the Outrigger Control Box. To extend or not depressed and the swing brake control valve
retract an outrigger component, first select the component disengaged, hydraulic pressure is applied to the brake,
overcoming spring pressure and releasing the brake. 3
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with the Outrigger Selector Switch (2,3,4,5), then select
extend or retract with the Extend/Retract Switch (6,7 Depressing the pedal actuates a swing power brake valve to
Figure 3-11). apply pressure to the brake assembly. This pressure aids the
spring pressure to overcome the hydraulic pressure being
FOOT PEDAL CONTROLS applied to the brake release circuit and applies the spring
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MISCELLANEOUS CONTROLS AND clockwise), the switch will override and prevent the RCL from
INDICATORS locking out the three craning functions (boom down,
telescope extend, and hoist up) should an overload or two-
Fuse Panel block condition occur.
Overriding the RCL with this switch should only be done in
The fuse panel (1) (Figure 3-13) is located behind the cab
the case of an emergency or when servicing the boom.
seat and on the cab fuse and relay panel assembly. It
contains up to 20 fuses that protect the various electrical A flashing light on the RCL display indicates the switch has
components of the crane. been activated.
The buzzer (2), located behind the cab seat, sounds when 1
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the following conditions exist:
• the ignition switch is turned to RUN; buzzer will sound
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for two seconds
• after the engine is started until the proper engine oil 2
pressure is reached
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• engine stop
• emergency stop switch activated
• transmission service
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• low brake pressure
• high hydraulic oil temperature
7649-9
• high transmission oil temperature FIGURE 3-13
• low steer pressure condition (for CE units)
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• hoist third wrap condition (for CE units) Rated Capacity Limiter (RCL) Emergency
Override Switch and Indicator (CE Certified
Rated Capacity Limiter (RCL) Emergency Cranes)
Override Switch (Non-CE Certified Cranes)
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WARNING
WARNING Loss of RCL Monitoring Hazard!
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Loss of RCL Monitoring Hazard! The RCL Emergency Override Switch is to be used in
The RCL Emergency Override switch is to be used in emergency situations only.
emergency situations only. Do not operate the crane with the RCL overridden during
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Do not operate the crane with the RCL overridden during normal operations.
normal operations. When the RCL is overridden, always have a helper on the
When the RCL is overridden always have a helper on the ground to signal you.
ground to signal you.
The RCL system, when programmed accurately, will lockout
The RCL system, when programmed accurately, will lockout the three craning functions—boom down, telescope extend,
the three craning functions—boom down, telescope extend, and hoist up—when a lift is attempted at or above the crane's
and hoist up—when a lift is attempted at or above the crane's capacity or when a two-block condition exists. Locking out
capacity or when a two-block condition exists. Locking out these three functions prevents the overload or two-block
these three functions prevents the overload or two-block condition from worsening.
condition from worsening.
The RCL emergency override switch is located inside a key-
The RCL emergency override switch (3, Figure 3-13) is a key locked single-door enclosure (1, Figure 3-14) that is
operated switch that is located inside the operator cab on the attached to the outside rear of the operator's cab. The switch
panel assembly behind the seat. When actuated (turned is a two-position momentary rocker switch with integral
indicator that, when actuated, will override and prevent the Backup Alarm (Not Shown)
RCL, for a period of 30 minutes, from locking out the three
craning functions (boom down, telescope extend, and hoist The backup alarm is an audio system used to warn
up) should an overload or two-block condition occur. personnel outside the crane when the crane is backing up.
The alarm system is electrical and consists of the backup
Overriding the RCL with this switch should only be done in alarm and its associated wiring. The alarm is connected to
the case of an emergency or when servicing the boom. the electrical wiring for the transmission reverse solenoids. It
The indicator in the override switch will illuminate red and the is activated when the transmission shifter is in the reverse
RCL and A2B override indicators on the RCL display will position. The backup alarm is installed in the rear outrigger
flash to indicate the switch has been activated. Upon box behind the grill plate.
activation, all craning function movements are reduced to
15% of their normal maximum speeds. Emergency Exit
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The RCL override function is automatically cancelled after 30 The windshield is considered the Emergency Exit. In an
minutes. The RCL override function can also be cancelled by emergency, push out on the windshield and escape through
the operator by either pressing the RCL emergency override the opening.
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switch a second time, by turning off the engine, or by turning
the crane function power switch off. OPERATING PROCEDURES
Refer to the RCL operator's manual for more information. Pre-Starting Checks
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A complete walk-around visual inspection of the crane
should always be made with special attention to structural
damage, loose equipment, leaks, or other conditions that
would require immediate correction for safety of operation.
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1 The following checklist items are suggested specifically for
the operator’s benefit to make certain his crane is prepared
for starting the day’s work.
Fuel Supply
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Check the fuel level and make sure the cap is on tight.
Engine Oil
Check the oil level in the crankcase and fill to the FULL mark
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Engine Coolant
7649-36
FIGURE 3-14 Check the coolant level in the radiator surge tank sight
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The Rated Capacity Limiter (RCL) Internal Light Bar is Check that the battery cables and clamps are tight and not
located on the upper left hand corner of the crane cab. The corroded.
RCL is an operational aid that warns a crane operator of
approaching overload conditions and over hoist conditions Signal and Running Lights
that could cause damage to equipment and personnel.
Check all signal and running lights for proper operation.
Replace burned out lamps with those of the same number or
Strobe Light or Beacon (Optional) (Not equivalent.
Shown)
Foot and Parking Brakes
The strobe light or beacon is on the roof of the cab. It is on
when the ignition switch is on. Check the foot and parking brakes for proper operation.
Daily Lubrication
Make certain that all components requiring daily lubrication
have been serviced. (Refer to Lubrication, page 5-1.)
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Inspect hoist rope in accordance with applicable Federal
Regulations. • Fluids suitable to -29°C (-20°F)
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Inspect sheaves, guards, guides, drums, flanges, and any - Arctic windshield washer fluid
other surfaces that may come in contact with the rope for any - Arctic fuel
condition that could cause possible damage to the rope.
-40°C (-40°F) Package
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Hook Block
• Coolant heater (to circulate warm coolant through
Visually inspect for nicks, gouges, cracks, and evidence of heaters and engine)
any other damage. Replace any hook that contains cracks or
• Transmission heater
shows evidence of excessive deformation of the hook
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opening, including twist. Be sure the safety latch is free and • Swivel heater
aligned.
• Battery heater
Air Cleaner • Fuel line heater
Check filter and tubing for security.
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Regions with ambient temperatures below -9°C (15°F) are • Radiator shutters
considered arctic. The following recommendations are for • Air diverter
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Use particular care to ensure cranes operated in very cold • Cold weather alternator
temperatures are operated and maintained in accordance • Super-capacitor starting system
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at the current site of the crane. There is a danger of the overhead panel. The fan for the heating system delivers
explosion when using the heater around combustible warm air into an air distribution box. Air is circulated accord-
objects! Do not park the vehicle near objects that are ing to control settings and delivered into the crane cab by a
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flammable. fan through various air extraction and air delivery vents.
Use caution near the exhaust tailpipe as it will also
Do not cover vents with bags, articles of clothing, or any other
become very hot.
objects. Keep hot air inlet and hot air outlet free of dirt and
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foreign bodies. Soiled or blocked hot air lines may cause
NOTE: Operation of the heater is not permissible:
overheating and result in damage.
• At locations where flammable gas or vapors
are found or can be formed (example: at fuel The crane auxiliary cab heater can be operated while the die-
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stations and chemical factories) sel engine is running or is stopped as part of the programma-
ble auxiliary heating system). The standard hot water crane
• At locations where explosive dust is found or cab heater can also be turned on after the engine has started
can be formed (example: coal, wood or grain and is warmed to operating temperature.
dust).
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• There is a risk of suffocation when using the NOTE: When using the heater at high altitudes, the factory
heater! heater setting will need to be re-calibrated for
proper heater operation.
• Do not operate the heater in enclosed spaces
(example: garages). • Heating at altitudes up to 1,500 m (4,921 ft)
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To activate the heater, ensure the fuel supply valve from the Unlimited heating is possible
heater fuel reservoir is turned to the ON position. Ensure the
• Heating at altitudes over 1,500 m - 3,000 m and (4,921 ft
battery disconnect switch is turned to the ON position and
- 9,842 ft)
push the activation button at the heater control panel. A
green light will illuminate indicating the system is activated. Heating is possible for short periods at this altitude
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The start-up and shutdown cycles may take approximately 2 (example: driving over a mountain pass or taking a break
minutes for initialization. Ensure the coolant, transmission while travelling between job sites).
heater, swivel, battery heater, in-line fuel pump, in-line fuel
During longer stays, (example: construction job project), the
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Battery Heater
If machine is equipped with cold weather package, ensure
battery heater coolant valve is switched off in ambient
CAUTION
temperatures above -9°C (15°F). Engine Damage Hazard!
If “Ultra Low Sulfur” fuel is not used in engines that require
Air Diverter it, the engine warranty will be void. Engine performance
An air diverter directs warmed air collected from under the will quickly deteriorate and it may stop running.
engine hood when the temperature is below -9°C (15°F) to
preheat the air intake going to the engine. Operation Below -40°C (-40°F)
If machine is equipped with cold weather package, ensure For crane operation below -40°F, capacities shall be derated
air diverter is switched to outside air intake in ambient 3.67% of the capacities shown on the load chart for each
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temperatures above -9°C (15°F). 1.8°F below -40°F (1°C below -40°C).
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The super capacitor provides additional cranking during cold
The following procedures detail the actions that must be
weather startup. The super capacitor is connected to the
taken to properly warm the different crane components
standard batteries with an isolation relay. The positive relay
before operating the crane.
feed is activated when the key is in the crank and run
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positions.The super capacitor allows the starter to be NOTE: For temperatures below -9°C (15°F) refer to arctic
cranked for 30 seconds then cycled off for 60 seconds before lubricants and conditions in the Operator and
cranking again until the engine starts. Service Manuals.
If crane has been left with battery disconnected for an Before starting the crane, ensure the appropriate lubricants
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extended period of time, super capacitor will need up to 30 are used for the prevailing ambient temperatures in which
minutes to charge before having full cranking capacity. the crane will operate in (a list of lubricants and their
temperature ranges can be found in the Lubrication section
Charge of capacitor can be measured by the following:
of your crane’s Operator Manual, by contacting your local
• Turn battery disconnect to on position. Manitowoc distributor, or by contacting Manitowoc Crane
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Care directly).
• Press black button located on top of capacitor:
• If light flashes green, capacitor is charging and may not
successfully start machine. CAUTION
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• If light is solid green, capacitor is charged and ready for Crane Damage Hazard!
starting. Operating the crane with the incorrect lubricants and
fluids for the prevailing ambient temperature and/or failing
Any other color or flash pattern may indicate an error,
to adequately warm the crane prior to cold weather
reference decal located on capacitor.
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from - 40°C (-40°F) to 49°C (120°F). Refer to the applicable start and warm the crane using the cold weather
engine manual for proper specifications. procedures found in this Operator ’s Manual and
supplement before operating the crane at full load.
Use correct grade of fuel for the prevailing temperature.
Diesel fuel should have a cloud point of 6°C (10°F) less than Engine
the lowest expected temperature. In case of emergency,
kerosene may be added to the fuel to bring the cloud point Warm-up Procedures for All Temperature Ranges:
down to the required temperature.This will minimize clogging
1. Upon startup, allow the engine to idle for 3 to 5 minutes
of filters and small passages by wax crystals. The addition of
before operating with a load.
kerosene is NOT recommended for general use. Refer to the
Cold Weather Package and Lubricants, page 5-3 of this 2. Cold Engine Startup: After allowing the engine to warm
operator manual. by idling it for 3 to 5 minutes, slowly increase the engine
speed to provide adequate lubrication to the bearings
and to allow the oil pressure to stabilize.
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2. Shift the transmission into the highest gear and increase revolutions in the opposite direction.
the engine RPM to 1500 for 15 seconds, then allow the
engine RPM to return to idle. Axles
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3. Repeat Step 2 until the temperature of the transmission Warm-up Procedures for Temperatures Below -35°C
sump reaches normal operating temperature. (-30°F):
Alternate Warm-up Procedures for Rough Terrain (RT),
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1. Setup the crane on outriggers.
Truck Mount (TM/TMS), and Industrial Cranes:
2. Engage the transmission (see Transmission, page 3-25)
1. Setup the crane on outriggers. with 4-wheel drive selected (if equipped) and allow
2. Engage the transmission with 4-wheel drive selected (if crane to run at idle until temperature of the transmission
sump reaches normal operating temperature.
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equipped) and allow crane to run at idle until the
temperature of the transmission sump reaches normal NOTE: Warm-up operation of 4-wheel drive transmission
operating temperature. engaged in 2-wheel drive only could cause
NOTE: Warm-up operation of 4-wheel drive transmission transmission damage.
engaged in 2-wheel drive only could cause
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startup and is required at ambient temperatures below 4°C medium function speed (joystick position) until the fluid
(40°F). reaches at least 10°C (50°F). It is then recommended
Warm-up Procedures: that all crane functions be cycled to remove cold fluid
from all components and cylinders of the hydraulic
1. Without operating the hoist function, warm the hydraulic
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system.
oil (see Hydraulic Oil System, page 3-25).
• If there is any unusual sound coming from the crane’s
2. Once hydraulic system is warm, operate the unloaded hydraulic pumps or motors, stop operation and engine
hoist, in both directions, at low speeds several times to immediately and contact a Manitowoc distributor.
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Engine Operation
Starting and shutdown procedures for most diesel engines
generally follow the same pattern. Therefore, the following
procedures can be applied except where specific differences 1
are noted. (Refer to the applicable engine manufacturers
manual for detailed procedures.)
Starting Procedure
Make an under-the-hood inspection for fuel, oil, and coolant
leaks, worn drive belts, and trash build-up
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CAUTION
Health Hazard!
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Diesel engine exhaust can be harmful to your health. Only 7693-2 FIGURE 3-15
operate the engine in a well ventilated area or vent
exhaust outside. Warm Engine
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Unexpected Operation Hazard! NOTE: The engine ECM monitors the engine and, under
Before starting engine, apply parking brake and engage certain conditions, cycles the air heater on and off
the swing lock. at start-up and during operation.
The engine is equipped with an electric air heater grid at the
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air inlet elbow to aid in cold starting and reduce white smoke
at start-up. In the preheat mode, the engine should not be
CAUTION cranked until the Wait-to-Start lamp turns off.
Machine Damage! 1. Ensure parking brake is set to ON, position transmission
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Never crank the engine for more than 30 seconds during to neutral, and depress the service brake foot pedal.
an attempted start. If the engine fails to start after 30
NOTE: Engine will not crank unless the transmission shift
seconds, stop and allow the starter motor to cool for
lever is in neutral and the service brake foot pedal
approximately two minutes before attempting another
is depressed.
start.
The buzzer will sound upon turning the Ignition
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the crankcase to prevent hard cranking. Diesel fuel should when the engine starts. Do not push or hold the throttle
have a cloud point of 6°C (10°F) less than the lowest down. The ECM will automatically provide the proper
expected temperature. In case of emergency, white amount of fuel to start the engine.
kerosene may be added to the fuel to bring the pour point
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down to the required temperature.This will prevent clogging 3. Immediately check engine instruments and warning
of filters and small passages by wax crystals. The addition of lights for proper indication after starting.
kerosene is NOT recommended for general use.
Battery Disconnect Switch
CAUTION
Ensure Battery Disconnect Switch handle (1) (Figure 3-15) is Engine Damage!
in the ON position (handle shown in the OFF position)
If any warning light stays on or indicator(s) do not display
proper readings, shut down the engine and correct the
malfunction before resuming operation.
Cold Engine Detailed cold weather starting and operating procedures are
covered in the engine manual.
Idling the Engine
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at start-up and during operation.
NEVER race the engine during the warm-up period. NEVER
The engine is equipped with an electric air heater grid at the
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operate the engine beyond governed speed (as might occur
air inlet elbow to aid in cold starting and reduce white smoke in downhill operation or downshifting). Engine bearings,
at start-up. In the preheat mode, the engine should not be pistons, and valves may be damaged if these precautions
cranked until the Wait-to-Start lamp turns off. are not taken.
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1. Prior to starting a cold engine, ensure the Crane Shutdown Procedure
Function switch is positioned to OFF.
1. Allow the engine to operate at idle for about five minutes
2. Ensure the parking brake is set to On, position the to avoid high internal heat rise and allow for heat
transmission to neutral, and depress the service brake dissipation.
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foot pedal.
2. Turn the Ignition switch to OFF.
NOTE: The engine will not crank unless the transmission
shift lever is in neutral and the service brake foot Transporting the Crane
pedal is depressed.
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Do not drive the crane with the boom off center because
automatic oscillation lockout will occur, making the crane Fully retract the outrigger jack cylinders and properly store
subject to tipping on uneven surfaces. Center the boom the floats.
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over the front, turn the Swing Brake Switch to ON and Disengage Main Hydraulic Pump via pump disconnect for
engage the Turntable Lock Pin (if equipped). cold weather starting of the engine (Sub-Zero). Pump
must be re-engaged for travel.
Fully retract the boom and ensure the swingaway jib is
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properly stowed and secured. Use four-wheel drive only when greater traction is necessary.
(Refer to Four-Wheel Drive Operation, page 3-33 for
operating instructions.)
CAUTION
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Machine Damage! CAUTION
Traveling at speeds greater than 16 km/h (10 mph) with Machine Damage!
the fixed counterweight installed and the boom extension
On open ground, tow or pull only on the tow/tie-down lugs
stowed can result in axle failure if the boom angle is less
or with the optional pintle hook.
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than 10°.
Do not tow or pull in 1st gear with the Drive Axle Selector
When traveling at speeds greater than 16 km/h (10 mph)
Switch in two-wheel drive position. Severe damage to the
in the above configuration, ensure that the boom is
drive train will result. Always engage four-wheel drive.
elevated to an angle between 10° to 20° and the hook
block is stowed in the storage tray. Should the crane become mired down, use a tow truck or
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• Fully retract all boom sections. Exercise caution whenever driving the crane with the boom
elevated. Travel with the boom elevated is permitted if the
• Stow or remove the boom extension from the crane.
following steps are followed:
• Lower the boom to horizontal and position over the front
• Limit travel to firm, level surfaces.
of the crane.
• Inspect the route of travel prior to moving the crane. Pay
• Engage the swing brake and turntable lock pin.
particular attention to any changing conditions in the
• Either the hook block may be reeved over the main terrain being traversed. Also, avoid any overhead
boom nose or the headache ball may be reeved over the obstructions.
main boom nose or auxiliary boom nose; the other must
• Travel must be performed in a controlled fashion.
be removed. If the hook block or headache ball remains
reeved on the boom, it must be secured at the tie down • Do not exceed a speed of 24 km/h (15 mph).
on the carrier to prevent swinging.
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• Inflate tires to the recommended pressure for travel
• Inflate tires to the recommended pressure for pick and operations.
carry operations.
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• When using the towing attachments, the boom must
• Ensure the hydraulic tank is filled to the specified level. remain horizontal.
Ensure the fuel tank is over half full.
• Fully retract all boom sections.
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• Do not support any loads by the boom (i.e., no pick and
• Refer to Traveling with Boom Extension and/or Inserts
carry loads) while traversing a slope.
Erected, page 3-30 if the boom extension is in the
• Remove all cribbing or other non-standard accessories erected position.
from the crane.
• Position the boom over the front of the crane.
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• Avoid holes, rocks, extremely soft surfaces, and any
• Engage the swing brake and turntable lock pin.
other obstacles that might subject the crane to undue
stresses and possible overturn. • The hook block may be reeved over the main boom
nose. The headache ball may be reeved over the main
• Conduct all travel with the assistance of a ground person
boom nose or auxiliary boom nose. The block and ball
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Inc. recommendations. The operator of the crane assumes • Do not support any load from the boom (see Pick and
responsibility for determining the suitability of traveling on a Carry Load chart for limitations for this application).
slope. Traveling on a slope should only be attempted under
• Remove all cribbing or other non-standard accessories
the controlled conditions specified in these guidelines, and
from the crane.
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criteria defined in the above guidelines contact The • Ensure adequate clearance to any overhead
Manitowoc Company, Inc. for further guidance. obstructions that the crane may be required to travel
beneath.
Traveling with Elevated Boom
• Ensure that all personnel involved in the operation and
those working around the crane are aware of any
hazards that may be encountered and are trained about
WARNING how to avoid the hazards.
Overhead Objects Hazard
Contacting overhead objects while driving the crane may
result in death, severe injury, and/or equipment damage.
Traveling with the boom elevated should only be
attempted under the controlled conditions specified in this
section.
Traveling with Boom Extension and/or Inserts • Position the 10.1 m (33 ft) boom extension plus 12.2 m
Erected (40 ft) insert at the minimum offset. Stow the stinger
section on the boom base section, not on the extension
10.1 m (33 ft)/17.1 m (56 ft) Extension base section.
Follow the steps below when traveling with the extension • Travel only on a firm, level surface.
erected:
• Fully retract the main boom.
• Position the 10.1 m (33 ft) or 17.1 m (56 ft) boom
extension at minimum offset. If traveling with just the • Limit main boom angle to a minimum of 0° and a
10.1 m (33 ft) extension, stow the stinger section on the maximum of 20°.
boom base section, not on the extension base section. • Do not exceed a speed of 4 km/h (2.5 mph).
• Travel only on a firm, level surface. • Ensure main counterweight is installed.
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• Fully retract the main boom. • Position the boom over the front of the crane.
• Limit main boom angle to a minimum of 0° and a • Engage the swing brake and turntable lock pin.
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maximum of 40°.
• Remove hookblock from main boom nose.
• Do not exceed a speed of 4 km/h (2.5 mph).
• Headache ball may be reeved over boom extension,
• Ensure main counterweight is installed.
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hanging 0.9 m (3 ft) below sheave.
• Position the boom over the front of the crane.
Extended Travel
• Engage the swing brake and turntable lock pin.
Depending upon the tire manufacturer, the higher inflation
• Remove hook block from main boom nose. pressures normally specified for lifting on rubber are not
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recommended for site to site transfer over extended
• Headache ball may be reeved over boom extension,
distances. The higher static/creep 8 km/h (5 mph) inflation
hanging 0.9 m (3 ft) below sheave.
pressures may remain in the tire while operating the crane
10.1 m (33 ft)/17.1 m (56 ft) Extension Plus 6.1 m on site within a distance of less than 6.4 km (4 mi).
(20 ft) Insert
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traveling with just the 10.1 m (33 ft) extension and insert, start. (Refer to tire inflation chart in Load Chart Book.)
stow the stinger section on the boom base section, not After every one hour of travel time, regardless of ambient
on the extension base section. temperature, stop and allow the tires to cool off for at least
30 minutes. At the destination, the tires must be allowed
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• Travel only on a firm, level surface. to cool to ambient temperature before crane lifting on
rubber.
• Fully retract the main boom.
• Limit main boom angle to a minimum of 0° and a Traveling — Forward
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maximum of 20°.
• Do not exceed a speed of 4 km/h (2.5 mph).
CAUTION
• Ensure main counterweight is installed.
Machine Damage!
• Position the boom over the front of the crane. Engage the turntable lock pin for extended travel. Failure
• Engage the swing brake and turntable lock pin. to engage the lock pin may allow the superstructure to
swing uncontrolled, damaging the machine and/or
• Remove hook block from main boom nose. property.
• Headache ball may be reeved over boom extension,
hanging 0.9 m (3 ft) below sheave. 1. With the Transmission Shift Lever in the neutral (N)
position, start the engine and allow it to adequately
10.1 m (33 ft) Extension Plus 12.2 m (40 ft) Insert warm up.
Follow the steps below when traveling with the extension 2. Depress the Service Brake Foot Pedal.
and insert erected:
Traveling — Reverse
Traveling in reverse is accomplished the same way as
traveling forward, except for shifting the Transmission Shift
WARNING Lever to reverse (R). Refer to Traveling — Forward, page 3-
Run-away Crane Hazard! 30.
Releasing the parking brake while the low service brake
Traveling — Towing/Pulling
pressure indicator is illuminated and the buzzer is
sounding, indicating the service brakes are inoperable,
may result in the crane rolling away freely without the CAUTION
ability of the operator to stop the crane. Machine Damage!
Never release the parking brake while the low service Manitowoc recommends towing or pulling another vehicle
brake pressure indicator is illuminated and the buzzer is with the optional pintle hook (if equipped) or by attaching
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sounding. at a point no higher than the pintle hook height, or severe
damage may occur to the drivetrain.
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3. Disengage the parking brake. Do not tow or pull by attaching to the tie-down lugs unless
4. Position the Drive Axle Switch to either two-wheel high the attaching point is no higher than the pintle hook
or four-wheel low. height.
Use four-wheel drive when greater traction is necessary
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CAUTION to avoid severe damage to the drivetrain.
Use four-wheel drive only when more traction is required. Should the crane become mired down, use a tow truck or
tractor to free the vehicle. Severe damage to the
5. Lift Transmission Shift Lever up out of its detent and drivetrain may occur if the operator attempts to free the
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push the lever to the forward (F) position, then rotate the crane unassisted.
Transmission Shift Lever Knob to the first (1) gear
position. The gear selection “F1” will appear in the LCD To avoid severe damage to the drive train while using the
Display to indicate that forward propulsion and first (1) crane to tow or pull another vehicle, follow these
gear have been selected; if the Service Brake Foot recommendations:
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speed. For additional speed, continue shifting to a than the pintle hook height.
higher gear.
• Use four-wheel drive when greater traction is necessary.
(Refer to Four-Wheel Drive Operation, page 3-33 for
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tractor to free the vehicle. Severe damage to the
drivetrain may occur if the operator attempts to free the Front Wheel Steering
crane unassisted.
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Conventional front wheel steering is accomplished with the
steering wheel. This method of steering should always be
• Ensure the boom is in a horizontal position and not
used when traveling at higher speeds.
elevated above 0°.
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• Ensure the outrigger beams and stabilizers are fully
retracted with the floats properly stowed.
To avoid severe damage to the drive train while the crane WARNING
engine is disabled: Unexpected Operation Hazard!
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• Disconnect drivelines. Operate the rear steer ONLY at slow speeds for added job
• Disengage parking brake by manually turning parking site maneuverability.
brake adjustment until axle turns free.
Rear Wheel Steering
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• Secure steering to prevent turning while towing. Crabbing is accomplished with the steering wheel and the
• Conduct all travel with the assistance of a ground person Rear Steer Control Switch. Depending upon which direction
to warn the operator of any changing conditions in the the operator wishes to travel (crab), the steering wheel is
terrain being traversed. turned in the same direction as the Rear Steer Control
Switch. This permits driving the crane forward or backward in
a crabbing manner.
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6402-2
CAUTION
Four-Wheel Crabbing
Unintended Operation!
FIGURE 3-16
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When using the differential lock, steering characteristics
Four-Wheel Drive Operation may be affected.
Try to use four-wheel drive to gain adequate traction
If more traction is required due to slipping or spinning
before using the differential lock.
wheels, engage the front axle drive as follows:
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Do not operate the differential lock when traveling
downhill; at speeds above 10 mph; on hard, dry surfaces;
and/or during axle spin-out.
CAUTION
NOTE: The differential lock will not operate unless the
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2. Position the Transmission Shift Lever to the neutral (N) Follow steps below when engaging/disengaging the
position. differential lock function.
3. Position the Drive Axle Selector Switch to four-wheel 1. Lock differentials by pressing and holding the Axle
low. Differential Control Switch in the lock position;
disengage the function by releasing the switch.
NOTE: If Drive Axle Selector Switch is positioned to four-
wheel low, the Service Brake Foot Pedal is not 2. Lock/unlock differentials only when vehicle is standing
depressed, and the Transmission Shift Lever is not still or moving at a constant low speed with wheels not
in neutral (N) position, the Four-Wheel Drive slipping.
Indicator will flash and four-wheel drive function will
not engage.
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good judgement and drive at low speeds when operating Axle Oscillation Lockouts Operation
the vehicle with locked differentials. The following procedure should be used to periodically
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check the axle oscillation system and ensure that it is in
4. Lock the differentials only when maximum traction is
proper working condition.
needed on poor road or highway surfaces.
1. Ensure the tires are inflated to the recommended
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pressure. Refer to the Load Chart Book in the crane cab
for proper inflation pressures.
CAUTION 2. With the hook unloaded, the boom fully retracted and
Possible Loss of Vehicle Stability! centered over the front at no more than a 10° to 15°
boom angle, position the crane on a block or curb so that
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Do not lock the differentials when the vehicle is traveling
down steep grades and traction is minimal. one rear tire is approximately 15 to 30 cm (6 to 12 in)
above the level of the opposite tire.
5. Always unlock the differentials when the need for
3. Slowly swing the superstructure to the left or right until
maximum traction has passed or when traveling on good
the axle oscillation lockout valve is activated. This will
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moving, if the following conditions are met: touching the road surface and the opposite front tire
1. The crane is moving very slowly (creep speed). should be light or slightly off the road surface.
2. The wheels are not spinning at the time of engagement. 5. Release the swing brake and swing the superstructure
until it is centered over the front.
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control lever to hold the load.
NOTE: Always operate control levers with slow, even
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pressure.
Preload Check
After the crane has been readied for service, an operational
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check of all crane functions (with no load applied) should be
performed. The Preload Check is as follows: FIGURE 3-17
NOTE: Operate engine at or near governed RPM during The Load Charts are divided into structural strength and
preload check of crane functions. stability limits. This is shown by the bold line across the chart.
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Capacities above the line are structural strength limits and
Carefully read and become familiar with all crane capacities below the line are stability limits.
operating instructions before attempting a preload
check or operating the crane under load. The left column is the load radius, which is the distance from
the center of crane rotation to the load center of gravity. The
1. Extend and set outriggers.
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4. Raise and lower the cable a few times at various boom boom angle (in degrees) for that load. When the boom length
lengths. Ensure there is no kinking. or lift radius or both are between values listed, the smallest
load shown at either the next larger radius or next longer or
Using Your Load Chart shorter boom length shall be used.
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NOTE: One of the most important tools of every crane is Another important section is the range diagram. The range
the Load Chart found in the crane operator cab. diagram shows the operating radius and tip height that can
The Load Chart contains a large amount of information, be achieved at a given boom length and angle. If the
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which must be thoroughly understood by the operator. operator knows the radius and tip height required for a
specific lift, the angle and boom length can be quickly
The Load Chart contains outrigger capacity charts for fully determined from the range diagram. Or, if the boom length
extended, mid extended outriggers for the main boom and and angle are known, the tip height and operating radius can
boom extension, and fully retracted outrigger beams for main be quickly determined.
boom only. In addition, the Load Chart contains two on-
rubber capacity charts: 360° stationary, and pick and carry A lifting diagram is included to describe over side, over rear,
over front. and over front lifting areas. The lifting area diagram shows
that the locations of the outrigger jack cylinders in the fully
extended position are used to mark the boundaries of the
lifting areas.
A boom extension capacity chart and notes are included to
list the capacities for the extension length, load radius, and
boom angle.
Another section contains the notes for lifting capacities. Be Crane Functions
sure to read and understand all the notes concerning lifting
capacities. Setting the Outriggers
The load chart also gives weight reductions for load handling 1. Engage the Parking Brake.
devices such as hook blocks, headache balls, boom NOTE: The Parking Brake must be engaged to enable
extensions, etc., which must be taken into consideration as outrigger functions.
part of the load. Remember, the weight of any other load
handling devices such as chains, slings, or spreader bars 2. Position the outrigger floats directly out from each
must be added to the weight of the load. outrigger to where the outriggers will be properly
extended.
Proper Leveling of the Crane
ASME B30.5 specifies that if a crane is not level within 1% of CAUTION
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grade, the allowable capacities must be reduced. Therefore,
whether lifting on rubber or outriggers, it is essential that the Possible Machine Damage!
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crane is level to within 1% of grade. The bubble level that is Always depress one of the outrigger/selector switches
provided on the crane is calibrated to be accurate within 1% before positioning the outrigger extension/retraction
of grade. switch to extend or retract. Failure to do this may cause a
hydraulic lock against the individual solenoid valves,
To properly level the crane, the boom must be positioned
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preventing them from opening.
over the front of the crane, fully lowered to horizontal and
fully retracted (for cranes fitted with a boom rest, the boom
shall be stowed onto the rest). Raise and level the crane
using the outriggers; refer to Setting the Outriggers, page 3-
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36.
DANGER
A working crane may settle during lifting operations. Electrocution Hazard!
Frequently check the crane for level. When rechecking the
crane for level, the boom must be positioned over the front of To avoid death or serious injury, keep all parts of this
the crane, fully lowered to horizontal and fully retracted (for machine, the rigging, and materials being lifted at least 20
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cranes fitted with a boom rest, the boom shall be stowed feet away from electrical power lines and equipment.
onto the rest). If necessary, relevel the crane using the
procedures under Setting the Outriggers, page 3-36. 3. If extending the outrigger to the mid-extend or fully
extended position, depress the desired Extension
Bubble Level Adjustment Switch on the Outrigger Selector Panel and hold the
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DANGER
3. Place a miracle pointer level, carpenter level, or similar Tipping Hazard!
type device on a machined surface such as the turntable
bearing or bearing mounting surfaces. All four outrigger beams must be deployed to one of three
positions before beginning operation, which include fully
4. Using the outriggers, level the crane as indicated on the retracted, mid-extend, or fully extended; do not operate
leveling device used in step 3. the crane with the outriggers in any other position.
5. Using the bubble level indicator mounting screws, adjust
the bubble level indicator to show level. NOTE: More than one outrigger beam can be extended at
a time. However, to ensure that each outrigger is
fully extended, repeat step 3 for each outrigger
after a multi-outrigger extension.
4. After deploying the four outrigger beams to one of the
three proper positions (fully retracted, mid-extend, fully
extended), depress the desired Stabilizer Switch on the
Outrigger Selector Panel and hold the Outrigger If the crane is setup on outriggers and “On Outriggers” is
Extension/Retraction Switch to EXTEND. The chosen when programming the RCL (Figure 3-18), then the
appropriate jack cylinder begins to move. OMS indicates to the RCL the horizontal position of each of
the four outrigger beams. Based on this information, the RCL
Extend each jack cylinder, positioning the float as
will default to the most conservative outrigger beam
necessary, until the locking levers of the float engage the
configuration; that is, if three outriggers are fully extended
jack cylinder barrel.
and one is retracted, the RCL will select retracted as the
NOTE: More than one jack cylinder can be extended at a outrigger configuration. A confirmation of this outrigger
time. configuration is all that is needed (Figure 3-19). Refer to the
Rated Capacity Limiter Operator Handbook for detailed
5. Extend front jack cylinders approximately 8 to 10 cm (3 instructions.
to 4 in).
NOTE: Figure 3-19 depicts all four outrigger beams in the
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6. Extend rear jack cylinders approximately 8 to 10 cm (3 mid-extend position as indicated by the OMS and
to 4 in). RCL.
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NOTE: If crane is equipped with tilting cab, ensure cab is in
the lowered position before leveling machine.
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and the crane is level as indicated by the bubble level
indicator located on the right side of the cab.
NOTE: If it is suspected that the bubble level indicator is
out of adjustment, verify and adjust the bubble level
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using the procedures under Bubble Level
Adjustment, page 3-36.
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DANGER
Tipping Hazard!
The mid-extend outrigger beam lock pin must be engaged 8127-1
FIGURE 3-18
before operating on any beam from the mid-extend
position.
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2. Slowly extend or retract the outrigger beam, allowing the extension/retraction switch slightly while pulling
locking pin to drop into the hole in the top of the outrigger upward on the pin.
beam, engaging the outrigger beam at the desired
2. Retract the outrigger extension/retraction cylinder.
length.
Swinging the Boom
Stowing the Outriggers
1. Select the rear jack cylinders with the Stabilizer Selector
switches and hold the Extension/Retraction switch to
RETRACT until the rear jack cylinders have retracted DANGER
several inches.
Crushing Hazard!
2. Select the front jack cylinders with the Stabilizer Selector Death or serious injury could result from being crushed by
switches and hold the Extension/Retraction switch to moving machinery. Before activating swing, sound the
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RETRACT until the front jack cylinders have retracted horn and verify that all personnel are clear of rotating and
several inches. moving parts.
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3. Repeat steps 1 and 2 until the crane is resting on all four Keep the area beneath the boom clear of all obstructions
wheels and the jack cylinder floats are several inches off and personnel when lowering the boom.
the ground The operator must select the proper load chart and RCL
program for the outrigger position selected.
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CAUTION CAUTION
Crushing Hazard! Possible Machine Damage!
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Keep feet and hands clear of floats when unlocking the Never push or pull the swing control lever through neutral
floats from the jack cylinders. to the opposite direction to stop swing motion. Use the
swing brake foot pedal to stop swing rotation.
NOTE: Each jack cylinder float weighs approximately
32 kg (70 lb). NOTE: Automatic rear axle oscillation lockout will activate
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retracted. p u l l e d b a c k , t o w a r d t h e o p e r a t o r, t o s w i n g
COUNTERCLOCKWISE. Always operate the control lever
6. Depress the desired Extension rocker switch on the with a slow, even pressure. Use the swing brake foot pedal to
Outrigger Selector panel and hold the outrigger stop rotation, then position the swing brake switch to ON to
Extension/Retraction rocker switch to RETRACT. The prevent further rotation.
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Lowering the Boom If crane is equipped with an auxiliary hoist, push on the top of
the Telescope Control Foot Pedal to extend the boom.
Retracting the Boom
DANGER
Crushing and/or Tipping Hazard!
Keep the area beneath the boom clear of all obstructions WARNING
and personnel when lowering the boom. Crushing Hazard!
Long cantilever booms can create a tipping condition, When retracting the boom, the load will lower unless the
even when unloaded and in an extended, lowered hoist cable is taken in at the same time
position.
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For normal crane operation, ensure the Boom Manual/
Automatic Mode Selector Switch is positioned to automatic
CAUTION mode and the Boom A/B Mode Selector Switch is set to the
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Possible Machine Damage! desired boom telescoping mode.
When lowering the boom, simultaneously let out the hoist
If the crane is not equipped with an auxiliary hoist, pull the
cable to prevent two-blocking the boom nose and hook
Boom In/Out Control lever rearward, toward the operator, to
block.
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retract the boom.
The closer the load is carried to the boom nose, the more
important it becomes to simultaneously let out the hoist If crane is equipped with an auxiliary hoist, push on the
cable as the boom is lowered. bottom of the Telescope Control Foot Pedal to retract the
boom.
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To lower the boom, push the Boom Control Lever forward, Retracting the Boom Using the Boom Recovery Mode
away from the operator, and hold until the boom is lowered to
the desired position. The boom recovery mode is only to be used to recover the
boom in the event of a failure in the boom control system and
Extending the Boom must not be used to continue normal craning operations.
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Before extending the boom, ensure the large access manual mode position (press top of switch).
cover on top of the boom base section is installed.
3. Set the Boom Section 1/Section 2 Selector Switch to
When extending the boom, simultaneously let out the either section 1 or section 2.
hoist cable to prevent two-blocking the boom nose and
hook block. 4. Retract the boom using the procedure under Retracting
the Boom, page 3-39.
For normal crane operation, ensure the Boom Manual/ 5. Once the boom has been retracted, set the Boom
Automatic Mode Selector Switch is positioned to automatic Recovery Mode Switch to the Off position (press top of
mode and the Boom A/B Mode Selector Switch is set to the switch).
desired boom telescoping mode.
6. Position the boom in the normal travel position.
If crane is not equipped with an auxiliary hoist, push the
Boom In/Out Control lever forward, away from the operator, 7. Stop the engine and secure the crane until the failure in
to extend the boom. the boom control system has been corrected.
Lowering and Raising the Hoist Cable impending capacity when the system has been properly
preset by the operator. The control panel is mounted in the
front console of the operator cab. When an overload
condition is sensed, the system provides the operator with a
WARNING visual and audible warning, and locks out the control levers
to prevent lowering the boom, extending the boom, or raising
Crushing Hazard! the main or auxiliary hoist cables.
Keep the area beneath the load clear of all obstructions
Three additional features are included within the RCL
and personnel when lowering or raising the cable (load).
system:
Do not jerk the control lever when starting or stopping the
hoist. Jerking the lever causes the load to bounce, which • Swing Angle Set Limitation
could result in possible damage to the crane. • Work Area Definition
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NOTE: When the load is stopped at the desired height, the • Anti-two Block Device
automatic brake will engage and hold the load as Swing Angle Set Limitation allows left and right swing
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long as the control lever remains in neutral. angle to be preset. When the preset angle is reached, the
Lowering the Cable system will provide an audible warning.
Push the Main or Aux hoist control lever forward, away from Work Area Definition allows the crane operator to describe
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the operator, and hold until the hook or load is lowered to the the crane’s working area by setting up “virtual walls”. They
desired height. are referred to as virtual walls because they exist in the
system and are not real walls. The virtual walls represent
Raising the Cable obstacles (i.e. buildings, towers, poles, etc.) in the crane’s
working range. They are set by defining points along the
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Pull the Main or Aux hoist control lever back, toward the
operator, and hold until the hook or load is raised to the outer limits of the working area with the tip of the boom. Once
desired height. the working area has been defined, the system will provide a
visual and an audible warning if the boom approaches a
Hoist Speed Range Selection virtual wall.
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CAUTION CAUTION
Possible Machine Damage! Possible Machine Damage!
Do not change the hoist speed range with the hoist When defining virtual wall(s), always allow a safe working
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Operational Aids
WARNING
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Stowing and Parking
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WARNING
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Tipping Hazard!
Never park the crane near holes, or on rocky or extremely
soft surfaces. This may cause the crane to overturn,
resulting in injury to personnel.
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When parking the crane, do the following:
1. Park crane on a stable surface.
2. Remove load from the hook.
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4. Fully retract boom and position it in the normal travel Unattended Crane
position.
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unattended.
10. Shut down engine following proper procedures specified
Failure to comply with these instructions may cause death
in this manual and applicable engine manual.
or serious injury.
11. Remove keys.
The configuration in which the crane should be left while
12. Close and lock all windows, covers, and doors. unattended shall be determined by a qualified, designated
individual familiar with the job site, configuration, conditions,
and limitations.
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This Page Blank
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SECTION 4
SET-UP AND INSTALLATION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Boom Extension Rigging Mode . . . . . . . . . . . . . . . 4-8
Accessing the Hoist Area Erecting the Boom Extension . . . . . . . . . . . . . . . . 4-8
(Fixed counterweight units only) . . . . . . . . . . . . . 4-1 Stowing the Boom Extension. . . . . . . . . . . . . . . . 4-15
Travel Configuration . . . . . . . . . . . . . . . . . . . . . . . 4-1 Setting the Folding Swingaway Offset . . . . . . . . . 4-17
Working Position . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Erecting and Stowing the Bi-fold Boom Extension
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Installing Cable on the Hoist . . . . . . . . . . . . . . . . . 4-2 with the 6.1 m (20 ft) Insert . . . . . . . . . . . . . . . . . . 4-18
Erecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
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Boom Cable Reeving . . . . . . . . . . . . . . . . . . . . . . 4-3 Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Erecting and Stowing the Bi-fold Boom
Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Removable Counterweight (Optional) . . . . . . . . . 4-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
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GENERAL Travel Configuration
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DANGER
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Working Position
2 2
Place the hoist access platform hand rail (1) (Figure 4-2) and
step (2) (Fixed counterweight units only) into the working
position:
1. Pull out on the step locking pin (1) (Figure 4-2), slide the
step (2) out to the working position and release the
locking pin into the locking hole.
2. Remove two locking pins from hand rail (3) and rotate it
up into the working position, reinstall pins. 3
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7312
FIGURE 4-3
3. Insert the cable through the slot and position around the
anchor wedge (1) (Figure 4-3).
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NOTE: The end of the cable should be even with the
bottom of the slot for the anchor wedge (1).
1
2 4. Position the anchor wedge in the drum slot; pull firmly on
FIGURE 4-2 the free end (2) of the cable to secure the wedge.
7649-14
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CAUTION
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CABLE REEVING
NOTE: There are two types of cable (wire rope) available
on this crane; 6 x 37 and 35 x 7 (rotation resistant).
Within the limits of the load and range charts and permissible
line pull, multi-part lines allow the operator to raise a greater
load than can be raised with a single part line. Various cable
reeving (part line) is possible with the boom nose and hook
block, Figure 4-7 and Figure 4-8. This reeving should be wire ropes they produce. Their advice should be sought for
accomplished by a qualified rigger using standard rigging each specific type of wire rope a crane user intends to install
procedures. on a mobile crane.
In order to quick reeve the hook block without removing the When assembly is complete, raise the boom to a working
wedge socket on the end of the cable refer to Figure 4-4. position with a load suspended to firmly seat the wedge and
rope into the socket before the crane is used operationally.
CAUTION
If the socket is not positioned with the flat face toward the
boom sections, structural damage will occur.
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FIGURE 4-4
methods may be necessary depending upon work distortion of the rope strands, caused by the bend
conditions. If alternate methods are selected, the user is around the wedge, to adjust themselves at the end of the
responsible and should proceed in compliance with the line.
regulations in force. If there are any questions, contact your
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3. Make sure the live-loaded side (Figure 4-6) of the rope is When using method A, place a wire rope clip around the
directly in line with the ears of the socket and the dead end by clamping a short extra piece of rope to the rope
direction of pull to which the rope will be subjected. If the dead end. DO NOT CLAMP THE LIVE END. The U-bolt
rope is loaded into the socket incorrectly, under a load should bear against the dead end. The saddle of the clip
the rope will bend as it leaves the socket, and the edge should bear against the short extra piece. Torque the U-bolts
of the socket will wear into the rope causing damage to according to the torques listed in Table 4-1.
the rope and eventual failure.
NOTE: The use of swivels is not allowed in conjunction
4. Insert the end of a wire rope into the socket, form a loop with non-rotation resistant wire ropes
in the rope, and route the rope back through the socket
Other sources for information with which crane users should
allowing the “dead” end to protrude from the socket.
be familiar and follow is provided by the American Society of
Ensure the dead end of the rope is of sufficient length to
Mechanical Engineers, American National Standard, ASME
apply end treatment to the dead end after the wedge has
B30.5, latest revised. ASME (formerly ANSI) B30.5 applies
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been seated.
to cableways, cranes, derricks, hoists, hooks, jacks, and
5. Insert the wedge into the loop and pull the live end of the s ling s. I t stat es , in s ec tion 5 -1 .7 .3, “ (c) Swag ge d,
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rope until the wedge and rope are snug inside the compressed, or wedge socket fittings shall be applied as
socket. It is recommended that the wedge be seated recommended by the rope, crane or fitting manufacturer.”
inside the socket to properly secure the wire rope by Wire ropes are addressed in ASME B30.5, section 5-1.7.2,
using the crane’s hoist to first apply a light load to the live ROPES, It states, in pertinent part, “(a) The ropes shall be of
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line. a c onst ruction rec ommende d by the ro pe or crane
manufacturer, or person qualified for that service.” Additional
6. After final pin connections are made, increase the loads
information is published by the Wire Rope Technical Board in
gradually until the wedge is properly seated.
the Wire Rope Users Manual, latest revised.
7. The wire rope and wedge must be properly secured
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inside the socket before placing the crane into lifting Table 4-1
service. It is the wedge that secures the wire rope inside WIRE ROPE CLIP TORQUE VALUES
the socket whereas the dead-end treatment is used to Clip Sizes *Torque
restrain the wedge from becoming dislodged from the mm Inches Nm Ft-Lbs
socket should the rope suddenly become unloaded from 3.18 1/8 6 4.5
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the headache ball or hook block striking the ground, etc. 4.76 3/16 10 7.5
Sketches A through F (Figure 4-7) illustrate various methods 6.35 1/4 20 15
for treating the dead-ends of wire ropes which exit a wedge 7.94 5/16 40 30
socket assembly. While use of the loop-back method is 13.28 3/8 60 45
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Of the methods shown below, Grove prefers that method A 19.05 3/4 175 130
or F be used on Grove cranes, i.e., clipping a short piece of 22.23 7/8 300 225
wire rope to the dead-end or using a commercially available 25.40 1 300 225
specialty clip or wedge. Typically, it is recommended that the 28.58 1-1/8 300 225
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tail length of the dead-end should be a minimum of 6 rope 31.75 1-1/4 490 360
diameters but not less than 15.2 cm (6 in) for standard 6 to 8 38.68 1-3/8 490 360
strand ropes and 20 rope diameters but not less than 38.10 1-1/2 490 360
15.2 cm (6 in) for rotation resistant wire ropes.
*The tightening torque values shown are based upon
the threads being clean, dry, and free of lubrication.
Specialty Clip
Specialty Wedge
A B C D E F FIGURE 4-7
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Upper Boom
Nose Sheaves To Hoist
Bottom Boom
Nose Sheaves
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Ball
To Hoist
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SINGLE PART LINE
TO HOIST
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0° OFFSET
6415-1
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Ball
To Hoist To Hoist
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FIGURE 4-8
Upper Boom
Nose Sheaves
To Main Hoist
Bottom Boom
Nose Sheaves
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Boom Nose
Dead End
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Hookblock
Sheaves
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ERECTING AND STOWING THE BI-FOLD • Extension of the boom in Manual Mode, with Boom
BOOM EXTENSION Section 2-4 selected.
The Boom Extension Rigging Mode requires that the boom
Description be extended in Auto Mode with B Mode selected, or Manual
Mode with Section 1 selected until the boom automatically
A 10.1 m (33 ft) fixed offsetable or a 10.1 to 17.1 m (33 to 56
stops and is clear of the guide ramps and stowage pins on
ft) folding offsetable swingaway boom extension is provided
the front and rear stowage brackets.
to obtain additional boom reach.
To exit the Boom Extension Rigging Mode the boom must be
The boom extension mounts directly to the boom nose
fully retracted causing the section 1 and section 2 proximity
utilizing a four point attachment. In addition, the swingaway
switches to be activated. Upon exiting the Boom Extension
can be stowed on the right side of the boom base section.
Rigging Mode, restrictions of boom operating modes are
Removing the attach pins from the attach points on the left removed.
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side of the boom nose allows the swingaway to be rotated
and stowed on the right side of the boom base section. Erecting the Boom Extension
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The fixed swingaway weighs approximately 774 kg (1706 lb) 1. Fully extend and set the outriggers.
and the folding swingaway weighs approximately 1102 kg
2. Position the boom over the front.
(2430 lb).
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3. Set the boom manual/automatic mode selector switch to
the AUTO position.
4. Set the boom A/B mode selector switch to the B mode.
DANGER
Before attempting to erect or stow the boom extension; 5. If extended, fully retract all the boom sections and lower
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read and strictly adhere to all danger decals installed on the boom to minimum elevation to permit ease of
the boom/boom nose, boom extension, and stowage installation of pins and access to the boom nose.
brackets. NOTE: The auxiliary boom nose (rooster sheave) does not
Lifting over the bi-fold extension base section is strictly have to be removed. However, if reeved, the hoist
cable must be removed from the sheave.
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5
13 8
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6056
9
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FIGURE 4-10
7 3
1
2
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6160
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Item Description
Boom Extension Base
1
Section
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2 Adjusting Bolt
5
3 Upper Hanger
6
4 Main Hanger
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5 Lower Support
6 Lock Hitch Pin
DETAIL A 6058
7 Adapter
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2
1
3
Item Description
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4 Front Mount
5
5 Hanger
DETAIL B
6058
Item Description
Boom Extension Base
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1
Section
2 Boom Extension Fly Section
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3 Shock Wear Pad and Shim
4 Ramp Wear Pad and Shim
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DETAIL C
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Item Description
3
1 Boom Extension Base Section
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2
4
Item Description
Boom Extension Base 7
1
Section
3
2 Boom Extension Fly Section
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3 Fly Sheave 4
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4 Cable Retainer Pins
5 Latch Hook
6 Spring
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7 Latch Bar
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DETAIL E
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Item Description
1 Boom Nose Upper Sheaves 1
8
2 Mast Assembly
3 Offset Links
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8
Pins
Boom Extension Attachment
9
Pins Stowage Lugs
7
10 Offset Link Pins 5
3
11 Zero Degree Offset Holes 4
6
8. Pull down on the handle to disengage the spring loaded 10. Attach a length of rope to the extension base section tip
boom stop block. Place the end of the handle in the to aid in the extension of the swingaway into place
retainer plate. Fully retract the boom. ahead of the boom nose.
NOTE: When the boom retracts, the handle will be NOTE: If erecting the boom extension fly section with the
released allowing the stop block to engage when boom extension base section, skip to step 15. If not
the boom is extended. erecting the boom extension fly section, perform
steps 11 to 14.
NOTE: The length indication on the rated capacity limiter
(RCL) will display 0 (zero) when the spring-loaded 11. Remove retainer clip from base to fly attachment pin and
stop block is in the working position (engaged) and remove attachment pin from base section to fly section
the boom is fully retracted. During the process of attachment fittings.
stowing and erecting the boom extension, the RCL
12. Stow the pin in the opposite attach fitting or the stowage
may display a negative dimension when the stop
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lug.
block is retracted (disengaged) and the boom is
fully retracted. 13. Ensure the pin attaching the fly section to the boom base
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section rear stowage bracket (Figure 4-10), (Detail D) is
in place.
14. At fly section sheave end (Figure 4-10), (Detail E) push
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in on the spring loaded latch hook to release latch,
allowing the base to separate from the fly. Skip to step
16.
15. Remove the pin attaching the fly extension section to the
boom base section rear storage bracket (Figure 4-10,
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Detail D). Ensure that the latch hook at the fly section
sheave end (Figure 4-10, Detail E) is latched.
16. Remove the lock hitch pin securing the extension base
to the front stowage bracket (Figure 4-10, Detail A).
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2 8177-2
Item Description
DANGER
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1 Boom Extension When erecting the boom extension, ensure that all
2 Boom Nose personnel and equipment are kept clear of the swing path.
3 Alignment Jack
18. Slightly raise and/or lower the boom to help control the
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FIGURE 4-10 continued extension. Using the rope attached to the tip of the
extension, swing the extension into place ahead of the
9. Remove the retainer clips from the attachment pins boom nose, engaging the anchor fittings with the
stowed in the base of the boom extension and insert the attachment fittings on the left side of the boom nose.
attachment pins through the attachment and anchor
fittings on the right side of the boom nose. Install the
retainer clips in the attachment pins.
DANGER
Do not modify the attach points to permit the installation of
CAUTION the attach pins.
If the boom extension fly section (stinger) is not to be
erected, it should remain on the stowage brackets on the 19. Install the attachment pin into the upper left anchor and
side of the boom. attachment fitting of the boom nose. Install retainer clip
in attachment pin.
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extension base section. 6642-20 FIGURE 4-12
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boom extension where dummy plug was removed.
DANGER
Do not attempt to erect the fly section unless it was
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attached to the boom extension base section during the 1
initial erection procedure.
e. Install the attachment pin into the anchor and 4. Lower the boom, then extend the boom only enough to
attachment fittings on the left side of the base disengage the spring loaded boom stop block.
section.
5. Pull down on the handle to disengage the spring loaded
f. Lower the boom and remove the rope from the tip of boom extension stop block (Figure 4-14). Place the end
the extension. of the handle in the retainer plate.
NOTE: Refer to Setting the Folding Swingaway Offset,
page 4-17 to obtain a 25 or 45 degree offset with
the swingaway.
27. Remove the cable retainer pins and clip pins from the tip
of the extension base section or extension fly section.
NOTE: For zero (0) degree offset, leave the mast
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assembly in the stowed position.
28. Remove the mast assembly clip pin and pin from the
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stowed position on the extension and raise the mast
assembly to an upright position. Install the pin and clip
pin. Remove the cable retainer pin and clip pin from the
mast.
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NOTE: The hoist cable is not routed over the base
extension sheave when using the fly extension.
29. Route the hoist cable over the mast sheave, the rollers
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on the adapter, the roller on the fly extension, and the
sheave on the extension tip. Install the cable retainer FIGURE 4-14
pins and clip pins.
6. Fully retract the boom.
NOTE: Do not reeve hoist cable through sheaves on the
NOTE: When the boom retracts, the handle will be
main boom nose.
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degree offset. Refer to Setting the Folding the boom is fully retracted. The RCL may display a
Swingaway Offset, page 4-17. negative dimension when the stop block is
retracted (disengaged) and the boom is fully
NOTE: If so equipped, the folding fly section must be
retracted during the process of stowing and
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3. Set the boom A/B mode selector switch to the B mode. a. Remove connector (1, Figure 4-15) from junction
box on boom nose.
1 DANGER
When stowing the fly extension, ensure that all personnel
and equipment are kept clear of the swing path.
6642-21 FIGURE 4-15 e. Elevate the boom and push in on the fly section to
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engage the spring loaded latch hook (Detail E) on
b. Install dummy plug (1, Figure 4-16) on junction box. the base section. Ensure the latch hook is properly
engaged.
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f. Lower the boom and remove the rope from the fly
section.
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12. Lower the boom to minimum elevation.
13. Attach a length of rope to the base extension tip.
14. Raise the boom to horizontal.
15. Extend the boom approximately 12 in so that the
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extension base and fly stowage lugs will line up in front
of the guide ramps and pins on the stowage brackets
when the swingaway is positioned to the side of the
boom.
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19. Remove the retainer clip and attach pin from the anchor
and attachment fitting on the top left side of the boom
nose; stow all pins in the base of the base extension.
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1 DANGER
When stowing the extension, ensure that all personnel
and equipment are kept clear of the swing path.
6642-19 FIGURE 4-17
20. Raise and/or lower the boom to help control the
11. If erected, stow the extension fly section as follows: swingaway and using the rope attached to the tip of the
base extension, swing the base extension to the side of
a. Attach a length of rope to the fly extension tip. the boom.
b. Raise the boom to horizontal. 21. Elevate the boom and push in on the extension to align
c. Remove the retainer clip and attachment pin from the stowage lugs on the extension with the guide ramps
the anchor and attach fittings on the left side of the and pins on the stowage brackets and fully retract the
base section and stow in the base section. boom.
22. Ensure that all of the stowage lugs on the base and fly Setting the Folding Swingaway Offset
are fully engaged with the pins on the stowage brackets.
23. Fully lower the boom.
24. Install the pin securing the extension base to the front DANGER
stowage bracket (Figure 4-8), (Detail A). Ensure the lock
Crushing Hazard!
hitch pin is pushed all the way in.
Ensure any blocking material used is adequate to support
25. Install the pin attaching the fly section to the boom base the weight of the extension assembly without tipping or
section stowage bracket (Figure 4-10), (Detail D). falling.
NOTE: If the fly extension section remained on the boom
stowage brackets, perform steps 26 through 29. 1. Extend and set the outriggers and swing the boom to
over the front. Position the boom to above horizontal.
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26. Remove retainer clip and attachment pin from the
bushing on base section. 2. Block under the tip of the extension assembly section.
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27. Insert the attachment pin into the base section to fly 3. To set the offset from a lesser degree to higher degree
section attachment fittings and install the retainer pin. perform the following procedures:
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section sheave end (Figure 4-10), (Detail E). CAUTION
29. Ensure the pin attaching the fly section to the boom base Possible Equipment Damage!
section stowage bracket (Figure 4-10), (Detail D) is in Do not overload the extension anchor fittings or the
place. extension base section when lowering the boom.
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30. Remove the retainer clips and attachment pins from the
anchor and attach fittings on the right side of the boom a. Slowly lower the boom until the pressure is relieved
nose and stow them in the base of the swingaway. on the offset link pins.
NOTE: For 25 or 45 degree offset, make sure the mast is in
the raised position.
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DANGER b. Remove the offset link clip pins and attach pins
Failure to maintain the proper clearance between the securing the offset links in the lesser degree offset
base extension anchor fittings and the boom nose attach position. If going to maximum offset stow them in
fittings could cause these fittings to contact each other the stowage lugs. If going to the intermediate (25
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during operation of the boom. degree) offset install them in the offset links for that
degree of offset.
31. Extend the boom in AUTO mode with B mode selected, c. Slowly elevate and telescope the boom at the same
or Manual Mode with Section 1 selected, until the boom time so that the extension does not move off of the
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stops. blocking until the offset links take the full weight of
NOTE: Reaching this stopping point is required for the the extension.
Boom Extension Rigging Mode process. d. Reeve the hoist cable as described under normal
erecting procedures.
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degree offset position align in the offset links. Install 7. Retract the boom leaving the bi-fold extension on the
the offset pins and clip pins. blocking.
c. Slowly elevate and telescope the boom at the same 8. Using the main or auxiliary hoist cable, lift the Insert by
time so that the extension does not move off of the the lifting lugs and position it at the base end of the bi-
blocking until the offset links take the full weight of fold extension.
the extension.
9. Mate the Insert to the bi-fold extension and install the
d. Reeve the hoist cable as described under normal four attaching pins and retainer clips removed in step 6.
erecting procedures.
10. With the hoist cable still attached to the Insert, lift the
assembled unit and move the blocking, erected in step
ERECTING AND STOWING THE BI-FOLD 5, to approximately 2.4 m to 3.0 m (8 ft to 10 ft) ahead of
BOOM EXTENSION WITH THE 6.1 M (20 FT) the boom nose attach end of the Insert.
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INSERT NOTE: Repeat steps 6 through steps 16 in a similar
manner to install the second Insert if applicable.
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11. Lower the bi-fold and insert assembly onto the blocks
DANGER and detach the hoist cable.
Crushing Hazard! 12. Retract the boom and lower to minimum elevation.
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Before attempting to erect or stow the bi-fold extension 13. Rig the hoist cable for single part line with nothing but
with insert, read and strictly adhere to all danger decals the wedge socket on the end of the cable.
installed on the boom/boom nose, boom extension, insert,
and stowage brackets. 14. Extend the boom and mate the attachment lugs on the
Insert with the anchor fittings on the boom nose. It may
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be necessary to raise or lower the boom slightly to mate
Erecting
the attach lugs.
1. Fully extend and set the outriggers.
NOTE: If the Insert attach lug holes are not in lateral
2. Position the boom over the front. alignment with the holes in the boom nose anchor
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Assembly. CAUTION
5. Extend the boom as necessary to permit sufficient Possible Equipment Damage!
clearance for installation of the 6.1 m (20 ft) Extension Do not attempt to swing the boom extension around to the
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Insert; then lower it until the tip of the bi-fold extension right side of the insert. This could result in damage to the
assembly is laying on the ground. Block up under the bi- insert.
fold extension, approximately 2.4 m to 3.0 m (8 ft to
10 ft) ahead of the boom nose. 16. Slowly elevate the boom and remove the blocking from
under the Insert and bi-fold extension.
6. Remove the four retainer clips and attachment pins that
secure the bi-fold extension to the boom nose. 17. Refer to steps 26 thru 30 of Erecting The Boom
Extension to erect the fly section, to set the offset, and
rig the hoist cable.
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3
4
7
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6055
FIGURE 4-18
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NOTE: If equipped, the folding fly section must be stowed 7. Attach the hoist cable hook to the lifting lugs on the
on the side of the base section. insert. Lift the assembly and reposition the blocking
approximately 2.4 m to 3 m (8 ft to 10 ft) forward of the
1. If the fly section is erected, refer to steps 1 thru 5 of insert to swingaway attachment points.
Stowing The Bi-Fold Boom Extension.
8. While supporting the insert with the hoist cable, remove
2. Extend the boom approximately 1.22 m to 1.52 m (4 ft to the retainer clips from the four pins attaching the insert to
5 ft). Lower the boom until the sheave is on the ground. the swingaway. Remove the four pins.
3. Block up under the insert approximately 2.4 m to 3.0 m 9. Remove the insert and position it to one side of the
(8 ft to 10 ft) forward of the boom nose. crane.
4. Remove the retainer clips from the four pins in the 10. Position the boom and extend it to engage the boom
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attachment and anchor fittings and remove the nose with the swingaway. Install the four attachment
attachment pins. Stow the pins in the holders on the pins and retainer clips removed in step 8.
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insert.
11. Stow the swingaway on the side of the main boom using
5. Retract the boom disengaging the anchor fittings on the steps 6 thru 26 of Stowing the Boom Extension, page 4-
boom nose from the attaching lugs on the insert. 15.
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FIXED COUNTERWEIGHT 6. Take up any slack on the lifting device and raise the
counterweight just enough to remove any pressure on
Description the left and right counterweight pin assemblies.
The counterweight (Figure 4-19) is pinned to the rear of the 7. Remove the pins from the superstructure frame lugs and
superstructure and weighs about 6540 kg (14,400 lb). For the counterweight. To remove each pin, push pin in and
cranes without an auxiliary hoist, an additional 672 kg turn it so its roll pin disengages from the related catch on
(1478 lb) counterweight is bolted to the hoist mounting area the counterweight.
instead of the auxiliary hoist. 8. Lower the counterweight enough to clear the
superstructure. Remove the counterweight from the
Maintenance crane and replace the retainer pins in mounting lugs.
9. Rotate the superstructure to the normal travel position.
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Installation
DANGER
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1. Fully extend and set the outriggers.
Crushing Hazard!
Death or serious injury could result from being crushed by 2. Rotate the superstructure so the counterweight will be
a falling counterweight. over the front of the carrier to gain additional clearance.
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Ensure the counterweight pin assemblies are installed
properly and are secure in their catches.
CAUTION
When lifting/handling the counterweight, keep the chains/ When lifting/handling the counterweight, keep the chains/
straps vertical to minimize side pull on the lifting lugs. straps vertical to minimize side pull on the lifting lugs.
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Removal NOTE: The counterweight weighs approximately 6540 kg
1. Fully extend and set the outriggers. (14,400 lb).
2. Rotate the superstructure so the counterweight is over Use of a forklift to install or remove the
counterweight is not recommended; damage or
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NOTE: Use of a forklift to install or remove the counterweight to the holes in the superstructure.
counterweight is not recommended. Damage or 4. Secure the counterweight to the superstructure with the
misalignment of the counterweight can result if a two pins. Secure the pin by pushing it in and turning it so
forklift is used for installation or removal. the roll pin engages the related catch on the
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4. Attach an adequate lifting device to the counterweight. counterweight. Release the pin so its spring can hold the
pin in place.
5. Adjust the four counterweight leveling bolts to provide
maximum clearance of the counterweight from the 5. Remove the lifting device from the counterweight.
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superstructure.
6. Using the four counterweight leveling bolts, level the Counterweight Plate
counterweight and eliminate any relative movement
The counterweight has a removable counterweight plate
between the counterweight and turntable. Maximum
attached to its rear wall with capscrews, flat washers and
height of counterweight shall not exceed 6 mm (0.24 in)
nuts. This plate weighs 395 kg (870 lb). Use appropriate
out of level with the turntable bearing when measured
caution and safety equipment in removing and installing this
from either counterweight outer edge.
plate.
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9
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5
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2
7064-2
FIGURE 4-19
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REMOVABLE COUNTERWEIGHT 7. Remove the attach pins from the counterweight lugs and
(OPTIONAL) cylinder ends. Raise the cylinders and stow the attach
pins in cylinder and insert retainer clip pins.
DANGER DANGER
Death or serious injury could result from being crushed by Travel is not permitted with the removable counterweight
a falling counterweight. on the carrier deck.
Ensure that all mounting pins are properly installed and
locked, during, and after operating the counterweight NOTE: The counterweight weighs approximately 6895 kg
removal system. (15,200 lb).
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8. Remove counterweight from the support weld on the
Removal front outrigger box before moving crane.
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1. Position the crane on a firm level surface. Fully extend 9. Using the crane’s boom and hoist or other crane, lift the
and set the outriggers. counterweight from the carrier deck to the auxiliary
2. Rotate the superstructure to align the counterweight with transport vehicle.
the support weld on the front outrigger box. Engaging
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the pin type turntable lock will aid alignment. Installation
NOTE: It may be necessary to jog the counterweight 1. Position the crane on a firm level surface. Fully extend
removal control valve switches to remove the and set the outriggers.
weight of the counterweight from the upper attach 2. Select the proper “Without Counterweight” operating
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pins. code on the RCL.
3. Using the counterweight removal control valve switches NOTE: The counterweight weighs approximately 6895 kg
(Figure 4-20), raise the counterweight cylinders to (15,200 lb).
relieve weight on the upper attach pins.
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3. Using the crane’s boom and hoist or other crane, lift the
counterweight from the auxiliary transport vehicle and
position the counterweight.
4. Rotate and align the rear of the superstructure above the
removable counterweight setting on the support weld on
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5 (4 places)
3 6670-1
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FIGURE 4-21
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Item Description
1 Removal Cylinders
2 Cylinder Attach Pins
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SECTION 5
LUBRICATION
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Environmental Protection . . . . . . . . . . . . . . . . . . . 5-1 Steering and Suspension. . . . . . . . . . . . . . . . . . . . 5-8
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Lubricants and Lubrication Intervals . . . . . . . . . . 5-1
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Standard Lubricants . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drive Train (continued) . . . . . . . . . . . . . . . . . . . . 5-14
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Arctic Lubricants and Conditions . . . . . . . . . . . . . 5-3
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Surface Protection for Cylinder Rods. . . . . . . . . . 5-6
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
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Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . 5-6 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
CraneLUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
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GENERAL • Always fill or add fluids with a funnel or a filling pump.
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Following the designated lubrication procedures is important • Immediately clean up any spills.
in ensuring maximum crane lifetime and utilization. The
procedures and lubrication charts in this section include LUBRICANTS AND LUBRICATION
information on the types of lubricants used, the location of INTERVALS
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federal environmental regulations. Chassis grease lubricants must not be applied with air
When filling and draining crane components, observe the pressure devices as this lubricant is used on sealed
following: fittings.
The multipurpose grease applied during manufacturing is
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• Do not pour waste fluids onto the ground, down any of a lithium base. Use of a non-compatible grease could
drain, or into any source of water. result in damage to equipment.
• Always drain waste fluids into leak proof containers that
are clearly marked with what they contain.
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Engine Oil Conoco Fleet Supreme EC CJ-4
6829104182 15W-40
Mobil Delvac 1300 Super
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Hydraulic/Transmission Oil Kendall Hyken 052 Must Meet John
Exxon Torque Fluid 56 Deere Std. JDM
Esso Torque Fluid 56 10W-20 J20c
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6829006444 BP-Eldoran UTH & Trak-Tran 9
BP- Blend- 7367
Exxon Mobil 424 10W-30
Hoist Gear/Swing Drive Oil Mobil: Mobilfluid 629 AGMA No. 4 EP
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6829100213
Texaco: Meropa 150
Grease, Multipurpose Citgo Lithoplex MP# 2
Texaco Starplex Moly # 2
Phillips 66 Philube M
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6829003477 NLGI 2
Mobil Mobilgrese XHP 222 Spe-
cial
Chemtool Inc, Lube-A-Boom
Open Gear Lube 6829102971 Fuchs Ceplattyn 300 Spray NLGI 1-2
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Fleetguard Complete EG
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
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the suitability of a specific fluid or lubricant.
• Coolant heaters (to circulate warm coolant through
When operating in cold weather and regardless of the oil
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heaters and engine)
viscosity of the crane’s lubricants, always follow the cold
weather start-up and operating procedures described in the • Fuel line heaters
Operator Manual to ensure adequate lubrication during • Transmission heater
system warm-up and proper operation of all crane functions.
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• Battery heater
Cold Weather Package and Lubricants • Engine hood insulation
Manitowoc recommends the following cold weather • Fan clutch
lubricants for use with ambient temperatures down to -29°C
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(-20°F) (TABLE 5-2) and -40°C (-40°F) (TABLE 5-3). But, • Radiator air shutters
these cold weather lubricants alone are not sufficient to • Air diverter box (to allow intake air to be taken in from
operate the crane in extreme low temperatures. Therefore, it under the engine hood)
is also recommended that the crane be equipped with the
following accessories: • Diesel fired cab heater
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Sunoco Duragear EP
Engine Oil Shell Rotella® T6 CJ-4
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Mobil Delvac 1 ESP
80056036 0W-40
Caterpillar Cat DE0-ULS Cold
Weather
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Transmission Oil Petro-Canada Duratran Syn- Must Meet John
thetic THF Deere Std. JDM
6829101559 J20c & J20d
Chevron All Weather THF
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Texaco TDH Oil SS
Hoist Gear/Swing Drive Oil Petro-Canada ENDURATEX AGMA No. 4 EP
6829103636 Synthetic EP 150
Mobil SHC629
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Fleetguard Complete EG
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
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Sunoco Duragear EP
Engine Oil Shell Rotella® T6 CJ-4
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Mobil Delvac 1 ESP
80056036 0W-40
Caterpillar Cat DE0-ULS Cold
Weather
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Transmission Oil Petro-Canada Duratran Syn- Must Meet John
thetic THF Deere Std. JDM
6829101559 J20c & J20d
Chevron All Weather THF
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Texaco TDH Oil SS
Hoist Gear/Swing Drive Oil Petro-Canada ENDURATEX AGMA No. 4 EP
6829103636 Synthetic EP 150
Mobil SHC629
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Petro-Canada
Supplemental Coolant Fleetguard DCA4
Additive (SCA) 6829012858 Fleetguard DCA2
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SURFACE PROTECTION FOR CYLINDER It is recommended that all exposed cylinder rods be
RODS protected using Boeshield® T-9 Premium Metal Protectant.
Manitowoc Crane Care has Boeshield® T-9 Premium Metal
Steel cylinder rods include a thin layer of chrome plating on Protectant available in 12 oz. aerosol cans by ordering part
their surfaces to protect them from corroding. However, number 9999101803 through the Parts Department.
chrome plating inherently has cracks in its structure which
Cylinder operation and inclement weather will remove the
can allow moisture to corrode the underlying steel. At typical
Boeshield® protectant; therefore, inspect machines once a
ambient temperatures, hydraulic oil is too thick to penetrate
week and reapply Boeshield® to unprotected rods.
these cracks. Normal machine operating temperatures will
allow hydraulic oil to warm sufficiently to penetrate these
cracks and if machines are operated daily, protect the rods. WIRE ROPE LUBRICATION
Machines that are stored, transported, or used in a corrosive Wire rope is lubricated during manufacturing so that the
environment (high moisture, rain, snow, or coastline
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strands, and individual wires in strands, may move as the
conditions) need to have the exposed rods protected more rope moves and bends. A wire rope cannot be lubricated
frequently by applying a protectant. Unless the machine is sufficiently during manufacture to last its entire life.
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operated daily, exposed rod surfaces will corrode. Some Therefore, new lubricant must be added periodically
cylinders will have rods exposed even when completely throughout the life of a rope to replace factory lubricant which
retracted. Assume all cylinders have exposed rods, as is used or lost. For more detailed information concerning the
corrosion on the end of the rod can ruin the cylinder. lubrication and inspection of wire rope, refer to Wire Rope in
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Section 1- Introduction in the Service Manual.
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LUBRICATION POINTS rust has not formed, otherwise the component must be
cleaned first.
A regular frequency of lubrication must be established for all
lubrication points. Normally, this is based on component Grease fittings that are worn and will not hold the grease
operating time. The most efficient method of keeping track of gun, or those that have a stuck check ball, must be replaced.
lube requirements is to maintain a job log indicating crane Where wear pads are used, cycle the components and
usage. The log must use the engine hourmeter to ensure relubricate to ensure complete lubrication of the entire wear
coverage of lube points that will receive attention based on area.
their readings. Other lubrication requirements must be made
on a time basis, i.e. weekly, monthly, etc. CraneLUBE
All oil levels are to be checked with the crane parked on a Manitowoc highly recommends the use of CraneLUBE
level surface in transport position, and while the oil is cold, l u b r i c a n ts t o i n c r e a s e y o u r c r a n e ’s r e l i a b i l i t y a n d
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unless otherwise specified. performance. Contact your Manitowoc distributor for
On plug type check points, the oil levels are to be at the information about Manitowoc’s CraneLUBE lubrication
program.
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bottom edge of the check port.
On all hoists with a check plug in the drum, the fill plug shall Safety
be directly on top of the hoist, and the check plug level.
To lubricate many of the locations the engine will need to be
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All grease fittings are SAE Standard unless otherwise started. After positioning areas of the unit for lubrication the
indicated. Grease non-sealed fittings until grease is seen engine must be turned off and the moved areas stable before
extruding from the fitting. One ounce(28 grams) of EP-MPG approaching.
equals one pump on a standard one pound (0.45 kg) grease
gun.
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Over lubrication on non-sealed fittings will not harm the
fittings or components, but under lubrication will definitely DANGER
lead to a shorter lifetime. Crushing Hazard!
Unless otherwise indicated, items not equipped with grease Movement of the superstructure and the boom may
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fittings, such as linkages, pins, levers, etc., should be create a crushing and/or pinching hazard. Failure to
lubricated with oil once a week. Motor oil, applied sparingly, observe this warning could result in death or serious
will provide the necessary lubrication and help prevent the injury.
formation of rust. An Anti-Seize compound may be used if
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Extreme
Until
Upper and Lower Pressure
2 Figure 5-1 grease 500 hours or 3 months 8 grease fittings
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King Pins Multipurpose
extrudes
Grease
6829003477
EP-MPG
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Extreme
Until
Fifth Wheel Pressure
3 Figure 5-1 grease 500 hours or 3 months 2 grease fittings
Pivots Multipurpose
extrudes
Grease
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6829003477
EP-MPG
Extreme
Until
Lockout Cylinder Pressure
4 Figure 5-1 grease 500 hours or 3 months 4 grease fittings
Pivot Pins Multipurpose
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extrudes
Grease
6829003477
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1 7114-17
4 2
7114-20
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3 7114-10
FIGURE 5-1
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NOTE: Lube level close enough to the hole to be seen or touched is not sufficient. It must be level with the hole.
When checking lube level, also check and clean housing breathers.
CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.
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CAUTION: If the makeup amount is substantially more than 0.23 l (0.5 pt), check for leaks.
• Check level every
GL-5 500 hours or 3 Fill to the bottom of
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Planetary Hubs Extended months the level hole in the
3.8 l
12 and Wheel Figure 5-2 Service Interval housing with the fill
(8 pt) • Drain and fill every
Bearings Gear Lubricant plug and the oil level
6829012964 4000 hours or 2 mark horizontal.
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CAUTION: Use of non-approved lubricant may damage components and/or invalidate published lubricant intervals.
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8130-1
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11 7114-17
5
12 7114-9
FIGURE 5-2
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6829104182 fuel); 250 hours beneath radiator
(>5000 ppm sulfur
fuel)
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• Check level every 10
hours or daily
• Drain and refill every
21a a. Transmission,
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1000 hours or 6
Torque HYDO Through fill pipe to
37.9 l months
Converter, Figure 5-3 Hydraulic Oil FULL mark on
(40 qt) • Change transmission
Dipstick 6829006444 dipstick
21b b. Filter filter after first 50 and
100 hours of service,
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then every 500 hours
thereafter
NOTE:
• Check the transmission fluid level with engine running at 850 rpm idle and the converter oil at 82°C to 93°C (180°F to 200°F). Do
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not attempt an oil level check with cold oil. To bring the oil temperature to this range, it is necessary to either work the crane or
stall the converter. Converter stall should be accomplished by engaging shift lever in forward high range with the brakes applied
and then accelerating the engine to half or three-quarter throttle. Hold the stall until the required converter temperature is
reached and stabilized. (Do not operate the converter at stall condition for longer than 30 seconds at one time. Shift to neutral for
15 seconds and repeat the procedure until the desired temperature is reached. Excessive temperature, i.e, 120°C (250°F)
maximum will cause damage to transmission clutches, fluid, converter and seals.)
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22 7649-27
21b 7649-26
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21a 7114-23
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Other Side
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23 7114-10
20b 7649-25
7795
Fill Location
FIGURE 5-3
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Replace secondary Right hand side of
Figure 5-4 --- ---
filter every third time engine hood.
primary filter is
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24b Pre-cleaner
replaced.
• In severe dust
conditions the pre-
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cleaner may need to
be serviced.
• Fuel filter is
• Change filter every
located on the
a. Fuel Filter 500 hours or 6
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25a intake manifold of
months.
Figure 5-4 --- --- engine.
b. Water • Drain water trap
25b • Water Separator
Separator every 10 hours or
is located near oil
daily.
cooler.
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NOTE: During replacement of the water separator, take note of the direction of the arrow. The arrow must point towards
the fuel filter
EP-MPG
Extreme
Until
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7649-15
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7114-11
26b
24a
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24b
Other Side
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7114-10
25b 7649-28
26a
7795 25a
FIGURE 5-4
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EP-OGL
Turntable Gear Open Gear Coat all
41a Figure 5-5 500 hours or 6 months Spray on
and Drive Pinion Lubricant teeth
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6829102971
EP-OGL
Turntable Swivel Open Gear
41b Not shown Coat pin 500 hours or 6 months Spray on
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Lock Pin Lubricant
6829102971
Until
EP-MPG
grease
Extreme
extrudes 2 grease fittings at
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Turntable Pressure
42 Figure 5-5 the whole 500 hours or 6 months the front of the
Bearing Multipurpose
circumfer- turntable.
Grease
ence of the
6829003477
bearing
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NOTE: Rotate the turntable 90° and apply grease to fittings. Continue rotating 90° and grease the fittings until the whole
bearing is greased.
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40
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7114-24
ce 42
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7649-21
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FIGURE 5-5
41a
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EP-MPG
ID of jack cylinder
Extreme
support tubes (4)
Jack Cylinder Pressure
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51 Figure 5-6 --- 50 hours or 1 week places and wear
Support Tubes Multipurpose
bands before
Grease
installing jack
6829003477
cylinders
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EP-MPG
Extreme
Jack Cylinder Pressure
52 Figure 5-6 --- 50 hours or 1 week Brush on
Barrels Multipurpose
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Grease
6829003477
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52
FIGURE 5-6
EP-MPG Until
Lower Lift
61 Figure 5-7 Extreme greases 500 hours or 3 months 2 grease fittings
Cylinder Pin
Pressure extrudes
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Multipurpose Until
Hook Block Grease
70 Figure 5-7 grease 250 hours or 3 months 1 grease fitting
Swivel Bearing 6829003477 extrudes
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Until
Hook Block 5 grease fittings -
71 Figure 5-7 grease 250 hours or 3 months
Sheaves 65 Ton
extrudes
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61 ce 7114-25 60 7114-16
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71
70
7114-32
FIGURE 5-7
Boom
Lube Point Figure Approved Lube Lube Operation
Item Application
Description No. Lubricant Capacity Interval Mode and
Length
Boom (continued)
NOTE: Crane Setup: Machine Shall be set up on firm level surface with fully extended outriggers and counterweight
installed. Ensure the crane is level.
Boom must be directly over the front and the swing lock engaged.
Set boom angle at zero degrees.’
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Do not exceed 38.1 m (125.3 ft) boom length in Auto Mode A.
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Do not exceed 34.2 m (112.3 ft) boom length in Auto Mode B.
All lubrication points can be accessed by operating the crane in the 0001 RCL operating mode by using both A and B boom
configurations.
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CAUTION: Do not operate the crane in RCL bypass to lubricate the boom.
• 12 places
• Extend
boom for
ce
Telescope access
Thoroughly 125 hours/
72 Cylinder Wear Figure 5-8 through • N/A
coat 3 months
Pads holes in
side of
sections 3
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&4
Thoroughly • 2 points
Tel 1 - Rear
coat all 15 places
internal Side 250 hours or • [B] 18.7 m
73A Figure 5-8 areas the • Extend
and Bottom EP-MPG 3 months (61.4 ft)
wear pad boom for
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boom
sections
Boom Tele 2, Thoroughly • Spread
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Boom
Lube Point Figure Approved Lube Lube Operation
Item Application
Description No. Lubricant Capacity Interval Mode and
Length
• 4points
• 16 places
EP-MPG • Extend
Thoroughly boom,
Extreme
Boom Tele 1 - coat all aligning
Pressure 50 hours or 1 • [B] 18.7 m
74A Rear Upper Figure 5-8 areas the grease
Multipurpose week (61.4 ft)
Wear Pads - wear pad fittings with
Grease
moves on
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6829003477 holes in
side of each
boom
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section
• 4 Points
• 16 places
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EP-MPG • Extend
Thoroughly boom,
Boom Tele 2, Extreme
coat all aligning
3, & 4 Rear Pressure 50 hours or 1 • [A] 34.2 m
74 B Figure 5-8 areas the grease
Upper Wear Multipurpose week (112.5 ft
wear pad
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Pads Grease fittings with
moves on holes in
6829003477
side of each
boom
section
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NOTE: Lubricate items more frequently than interval indicated in table if environmental conditions and/or operating
conditions necessitate.
CAUTION: Do not apply excessive pressure or force when greasing the wear pad, as this can cause the grease fitting to
separate from the wear pad. Only apply grease until resistance is felt.
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FIGURE 5-8
Boom
Lube Point Figure Approved Lube Lube Operation
Item Application
Description No. Lubricant Capacity Interval Mode and
Length
Boom (continued)
Boom Tele 1 Thoroughly • 8 Points
Section Lower coat all • 24 places
50 hours or • [B] 18.7 m
75A Front Upper and areas the by brush
1 week (61.4 ft)
Lower Wear EP-MPG wear pad
Pads moves on • Spread
Extreme
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grease on
Pressure the outside
Figure 5-9
Multipurpose Thoroughly of Tele 1,
Boom Section
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Grease coat all 2, 3, & 4 in
Lower Front and 6829003477 50 hours or • [A] 34.2 m
75B areas the the area
Upper Front 1 week (112.5 ft
wear pad that the
Wear Pads
moves on wear pads
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move on
NOTE: Lubricate items more frequently than interval indicated in table if environmental conditions and/or operating
conditions necessitate.
• 2 grease
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fittings
• Extend
Until Tele 1
Extend Cable 250 hours or approx. 3 ft • [B] 12 m
76a Figure 5-9 grease
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Grease • 4 grease
6829003477 fittings
Until • Extend
Extend Cable 250 hours or Tele 2 • [A] 12.8 m
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Boom
Lube Point Figure Approved Lube Lube Operation
Item Application
Description No. Lubricant Capacity Interval Mode and
Length
• 2 Points
• 2 grease
fittings
• Fully
extend
Tele 1,
then
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Until extend
Retract Cable 250 hours or Tele 2 until • [B] 26.2 m
77a Figure 5-9 grease
Sheaves 3 months grease (86 ft
extrudes
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fittings are
accessible
through
large
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access
hole in
EP-MPG side of
Extreme Tele 1
Pressure
ce
Multipurpose • 2 Points
Grease • 2 grease
6829003477 fittings
• Fully
en
extend
Tele 2 and
Tele 4,
then
Until access
Retract Cable 250 hours or • [A] 34.3 m
77b Figure 5-9 grease
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through
access
holes
toward the
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front of
Tele 2
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76a
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76b
5
75
75
FIGURE 5-9
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Pressure Until
Upper Boom 2 grease fittings
81 Figure 5-10 Multipurpose grease 250 hours or 3 months
Nose Sheave (1) per sheave
Grease extrudes
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6829003477
Until
Lower Boom
82 Figure 5-10 grease 250 hours or 3 months 5 grease fittings
Nose Sheave
extrudes
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Until
Auxiliary Boom
83 Figure 5-10 grease 250 hours or 3 months 1 grease fitting
Nose Sheave
extrudes
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81
82
83
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75
7114-27
7114-15
79
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FIGURE 5-10
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7114-30
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8130-2
7115-33
FIGURE 5-11
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AGMA • Check and fill every
50 hours or weekly the sight glass and
Extreme
14.7 l the level no more
93a Auxiliary Hoist Figure 5-12 Pressure Gear
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(15.5 qt) • Drain and fill every than 3 mm (0.13 in)
Lubricant 1000 hours or 12 from the top of the
6829100213 months sight glass
NOTE: Line up the Fill/Drain Plug with the upper access hole (A). Let hoist sit idle for 20 minutes for an accurate reading.
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If oil level is not visible in sight glass, the hoist is under filled. Oil escaping from vent plug (B) or is more than 3 mm
(0.13 in) from the top of the sight glass is an indication the hoist is overfilled. If hoist is over filled drain the oil from
the Fill/Drain Plug at the upper access hole. When replacing the oil, align the Fill/Drain Plug with the lower access
hole (C) and drain the oil.
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Failure to align the Fill/Drain Plug with the upper access hole prior to checking the oil level will result in an
inaccurate reading.
EP-MPG
Extreme
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A B 92
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FIGURE 5-12
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necessary
NOTE:
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• Environmental and other conditions can dramatically affect the condition of hydraulic oil and filters. Therefore,
specific intervals for servicing/changing hydraulic oil, filters and hydraulic tank breathers cannot be set.
However, it is imperative for the continued satisfactory performance of Grove cranes that inspections be
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performed on the basis of how and where each crane is used. Air borne and ingested contaminants can
significantly reduce the life of oil and the condition of hydraulic oil filters and tank breathers.
• Under normal operating conditions, it is recommended that hydraulic oil, filters and breathers be inspected
and oils sampled at least every 3 to 6 months and more frequently for severe operating conditions. The
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inspections should be for air borne and/or ingested particles and water that deteriorate and contaminate the oil
(e.g., oil appears “milky” or no longer has a transparent clear to amber color). The return filter by-pass
indicator should be observed daily to determine if the contaminants content may be high. If the indicator
reaches the red zone or indicates a by-pass condition, the hydraulic oil must be sampled. The hydraulic tank
breather should also be inspected to assure that it is not restricting air flow into and out of the reservoir.
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• To inspect hydraulic oil, fill a small glass container with a sample of reservoir oil and another glass container
with fresh oil. Let the samples stand, undisturbed, for one to two hours and then compare the samples. If the
reservoir oil is heavily contaminated with water the sample will appear “milky” with only a small layer of
transparent oil on top. If the “milky” appearance was due to air foaming, it will dissipate and the oil should
closely match the fresh oil. Should you have any questions, please contact your local authorized Manitowoc
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distributor.
• The hydraulic oil shall meet or exceed ISO 4406 class 17/14 cleanliness level.
HYDO
Change filter when the
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FIGURE 5-13
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FIGURE 5-14
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SECTION 6
MAINTENANCE CHECKLIST
SECTION CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Daily or 10 Hour Check List . . . . . . . . . . . . . . . . . . 6-1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Weekly or 50 Hour Check List . . . . . . . . . . . . . . . . 6-2
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GENERAL INSTRUCTIONS
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This section contains a list of daily inspection and Refer to your Service Manual for specific maintenance and
maintenance checks. Performing the checks will help adjustment procedures.
maintain the safety, dependability, and productivity designed
Refer to Section 5 - Lubrication (in this Operator Manual) for
into your crane.
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lubrication intervals, types of fluids and lube point locations.
Refer to your Inspection & Lubrication Service Log for further
requirements.
6 Boom Angle Indicator: Check for proper operation while operating machine.
7 Rated Capacity Limiter: Check for proper operation while operating machine. Check connectors and wiring for
proper alignment and insulation.
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8 Anti-two-block (A2B) Electrical and Hydraulic: Check for proper operation while operating machine. Check
connectors and wiring for proper alignment and insulation.
9 Brakes and Air System (if equipped): Check for proper working order. Check for proper operation while
operating machine. Drain moisture.
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10 Tires: Check for proper inflation/pressure. Check for excessive wear. Check for excess dirt, grease or foreign
matter.
11 Hourmeter: Check for proper working order. Check for proper reading while operating engine. Check connectors
and wiring for proper alignment and insulation.
12 Hydraulic Tank: Check for proper service/level. Check for excess dirt, grease, or foreign matter.
13 Hydraulic Oil Filter: Check for proper service/level.
14 Wire Rope: Check for damaged, frayed, or broken strands.
15 Hoists: Is item properly installed on machine. Check for excess dirt, grease, or foreign matter. Check for proper
operation while operating machine.
16 Boom and Attachments: Is item properly installed on machine. Check for excess dirt, grease, or foreign matter.
Check for proper operation while operating machine.
17 Crankcase: Check for proper service/level. Check for excess dirt, grease, or foreign matter.
6
Grove Published 9-29-2015, Control # 521-02 6-1
MAINTENANCE CHECKLIST RT770E OPERATOR MANUAL
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Weekly or 50 Hour Check List
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1 Sheaves: Check for proper operation, excessive wear, and damage.
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ALPHABETICAL INDEX
Accessing the Hoist Area (Fixed counterweight units only). . . . . . . . . . . . . . . . . . . . . . . 4-1
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cab Overhead Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cable Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Control Seat Assembly (Single Axis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Crane Warm-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Dead-End Rigging/Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
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Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Environmental Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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Erecting and Stowing the Bi-fold Boom Extension with the 6.1 m (20 ft) Insert. . . . . . . 4-18
Erecting and Stowing the Bi-fold Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Fixed Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Foot Pedal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
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Installing Cable on the Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
List Of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Lubricants and Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Miscellaneous Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Model Specific Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Noise/vibration test results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Side Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Steering Column Indicator and Gauge Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Temperature Effects on Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Transporting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Wind Forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Work Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Grove 7-1
OPERATOR MANUAL RT770E OPERATOR MANUAL
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